Golens Engine Service

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2 Golens Engine Service Jeep Six-Cylinder Setup Guide Thank you for purchasing a Golen performance engine. Your engine will give you many years of fun and reliability provided you properly follow these instructions for setup and break-in. The initial setup and break-in of your engine is the most critical part of its life and will determine how it runs for years to come. Please remember, just because an engine is built with top-end performance components doesn t mean it will run correctly with improper break-in and tuning. We highly recommend that you read through all of this information before starting your installation, that way you know what to expect throughout the process and may call the tech line and ask any questions before beginning the installation. Unpacking and Inspection Uncrate your engine and visually inspect it for any damage that may have occurred during shipping. If damage is visible, contact the freight carrier and GES immediately. Compare the GES engine to the engine you removed from your car. Make sure all mounting holes and other features are identical between the two. Remove, clean and thoroughly inspect the following parts from your original motor: oil pan, motor mounts, starter, flywheel, timing chain cover, fuel pump, water pump, intake manifold, injection, distributor and ignition components, thermostat, exhaust manifolds, harmonic dampener, oil and water temperature sending units, dipstick and rocker covers. This is a good time to replace any part that may have excessive wear. After inspection, install the parts on your GES high performance engine. We recommend installing the distributor and injection after the engine is bolted in to prevent damage to these components. Installation Install the engine into the engine compartment and bolt up all mounts. Inspect the following parts and their respective mounting hardware: air conditioning, alternator, power steering pump, smog pump, radiator, pulleys, fan, fan shroud, hoses, belts, etc. These parts can also have excessive wear and can be more easily replaced at this time. Install the fuel injection and throttle cable, then fill the radiator with the proper amount of coolant and check for leaks. Install a new oil filter and pour the required amount of oil (6 qrts) into the engine. It is mandatory to run a true break in oil such as Joe Gibbs BR or Royal Purple Break In, failure to do so can result and premature camshaft wear. You can run the break in oil for 500 miles as long as it stays clean, after that you can run either a Zinc based oil such as the Joe Gibb s Hot Rod oil or you can use a conventional or

3 synthetic 10/40 or 15/40 oil but you will need to add a Zinc Additive to every oil change with these for the entire life of the engine. Priming the Oil Pump At this point you need to prime your engines oil pump. This step is very important and can severely damage your engine and void your warranty if not performed properly. Please carefully follow the instructions included in this packet labeled How to Prime the Jeep Oil Pump then return to this page once this is complete. Installing the Distributor/Cam Sensor Now you should install the distributor. Follow the instructions included in this packet labeled Installing the Jeep Distributor/Cam Sensor then return to this page. Starting the Engine At this point, you are just about ready to start your engine. Reconnect the positive and negative battery cables and double-check all connections. Once this is complete, call the Golen Engine tech line at ext 2. This is a required part of our standard setup procedure and allows us to review all of the final details before starting your engine. Now you are ready to start your new engine. Keep in mind that you must break in the camshaft. This is just as important as priming the oil as you may also severely damage your engine and void the warranty by not performing this step. Please follow the instructions in Jeep Camshaft Break-In Procedure then return to this page. After the cam break-in has been completed, check for leaks. Be sure to check under the vehicle. Also check the spark plugs. The porcelain should be fairly clean, almost white. Brand new spark plugs will remain fairly clean after the cam break-in and should not be interpreted as a sign of a lean condition. If the spark plugs look black or do not look fairly clean after the cam break-in, please call the Golen Engine tech line at ext 2. Driving the Vehicle Now it s time to go for a drive. Run the engine in high gear and lug it checking for detonation (spark knock or ping). If you experience spark knock call Golen Engine to discuss. Next make a test run on the road reaching 30mph. Keep this first ride limited to 2-3 miles, then return and check the spark plugs. They should still be fairly clean, but may start showing a light brown color that will get slightly darker as you put more miles on the engine. This is a good sign and means your engine is running properly. If the spark plugs look black please call the Golen Engine tech line at ext 2. Periodically accelerate to 50mph and decelerate rapidly. Repeat this procedure at least 10 times. Applying loads to the engine for short periods of time causes increased ring pressure against the cylinder walls and helps seat the rings. The rapid deceleration increases vacuum and gives extra lubrication to the piston and ring assemblies. Drive normally but not at continuous high speeds or under heavy loads for the first 500 miles. It is important to not lug or baby the engine during break-in because the rings will not seat properly. Double check all bolt torques, hose connections, coolant and oil levels. We recommend that you check these items for the first two weeks of run time. It will take about 500 miles to break the engine in all the way. It is mandatory to run a Zinc based oil such as the Joe Gibb s Hot Rod oil or a Zinc Additive with every oil change for the entire life of the engine.

4 How to Prime the Jeep Oil Pump Golens Engine Service Priming the oil pump in your Jeep engine brings the oil pressure up to normal before the engine is started. This will protect the engine from premature failure cause by a dry start. Dry start is a condition whereby the engine is initially run for a short time without any lubrication on the bearings. This can wipe and spin bearings and cause quick and devastating damage to the engine internals. Priming the engine using the following instructions ensures that the first time it is started there is proper lubrication on all internal parts. Once the engine has been primed and run for the first time, a thin layer of oil always remains on all of the bearings and protects them for those first few critical seconds during startup while the pressure builds up. Priming the oil pump is the most important step to take just before starting your engine for the first time!! 1. After you install the engine into the Jeep s engine compartment, make sure that you install a new name-brand oil filter such as Wix and fill the engine with the proper amount of oil. Using the factory oil pan and oil dip-stick, fill to the factory level on the stick. 2. Install the priming tool into the engine through the distributor hole and attach a electric drill to the priming tool. If you don t have a priming tool, you may cut the handle off of a flat-head screwdriver and use that to turn the oil pump drive shaft. Be careful, though, as the cut-off end may be sharp. 3. Next, turn the drill clockwise until you feel the drill load-up. This may take a few minutes, but you will eventually feel the drill start to torque back on your arm. This is a sign that the oil has now been pulled through the oil pump pick-up tube and is now actually pumping through the engine. 4. Continue running the drill for another minute after the drill loads-up. This ensures that all of the bearings and moving components have been properly lubricated. 5. After priming is completed, install the distributor and start the engine. 6. If you have any questions regarding priming the oil pump, please call the GES tech line at Ext 2.

5 Installing the Jeep Distributor/Cam Sensor Golens Engine Service 1. Ensure the #1 piston is at Top Dead Center on the compression stroke. To find TDC on the compression stroke you can remove the #1 spark plug and put your finger over the spark plug hole while you have someone turn the engine over slowly by hand, once you feel pressure building up on your finger bring the piston to TDC and you ve got it. 2. Remove the distributor cap and rotor and look at the pulse ring on the distributor (see picture below), note that there are two holes one for the 2.5 (4) cylinder engine and one for the 4.0 (6) cylinder engine. (pulse ring is located under the rotor and my require you to remove the plastic dust cover to expose it) 3. Insert a 3/16 pin (an allen wrench will do) into the small hole under the bottom side of the distributor base. Then find the 4.0 (6) cylinder hole in the pulse ring which is located at the end of the half moon pulse ring and line the two up and lock out the pulse ring. Note: The hole that is free is to time the four cylinder engine, do not use for the six cylinder engine. 4. Pre-position the oil pump slot at 11 o clock to accept the distributor drive as shown in the picture below. 5. Insert the distributor, engaging the oil pump. Note: The rotor will not be aligned to the # 1 plug wire on the cap. Once the distributor is fully engaged and flush with the block remove the alignment pin. 6. Install and tighten the securing bolt at the base of the distributor. Do not rotate the distributor base at all for this will not change the ignition timing since this is actually a cam sensor for the engine

6 Golens Engine Service Jeep Camshaft Break-In Procedure Follow all of the steps in the Startup Guidelines before attempting to start your new Jeep Engine and make sure that you are using a true Zinc Based break in oil such as the Joe Gibb s BR or the Royal Purple Break In oil, this is mandatory in order to break the camshaft in properly Get the distributor set properly so the engine will fire off immediately by following the steps in Installing the Jeep Distributor/Cam Sensor. Start the engine and make sure you have oil pressure and a good idle for seconds without using any throttle. If it doesn t idle well, you need to shut the engine down and determine the cause of the problem before performing the cam break-in. If this occurs, call the Golen tech Ext 2, Monday through Friday, 9am to 5pm Eastern time. Assuming oil pressure and idle are good, bring the engine up to 2000 rpm. You will keep the engine at 2000 rpm for 20 minutes watching for oil or anti-freeze leaks, oil pressure, and engine temperature. Also listen for general engine operation. The lifters may take up to 20 minutes to complete pump-up and during this time may make some noise this is perfectly normal. You might also notice the header getting red hot if this happens shut the engine down and let it cool. Once the engine has had time to cool (about 30 min) the resume whatever time you have left on the 20 min break in. After the cam break-in has been completed, you need change the oil filter only, leave the expensive break in oil in the engine for the first 500 miles as long as it looks clean. After the filter has been changed, you may then perform the final inspection steps in Startup Guidelines. Note: You will need to use either a Zinc based oil such as the Joe Gibb s Hot Rod oil or at least a Zinc additive in every oil change for the life of the engine. Failure to follow this guideline will result in premature camshaft wear for sure.

7 Golens Engine Service Why Zinc in my oil? The Jeep inline 6 cylinder engine has what is called a flat tappet camshaft which requires certain oil additives one of which is Zinc. The Zinc additive puts a protective coating on all metallic parts inside the engine and the camshaft needs this more than any to guarantee a long life. Now you might be asking yourself why now? All early model engines from the 80 s and earlier came from the factory with a flat tappet camshaft. Well the US government noticed a few years ago that a huge percentage of newer vehicles were failing their local emissions tests. Once they looked into it they found that the Catalytic converters were failing due to the higher levels of Zinc that were present in the engine oil at the time. As all engines even brand new engines run they burn small amounts of oil through the combustion chamber and the Zinc was attacking the Cat s and causing them to break down prematurely causing the failed emissions tests. So as you can imagine the US government forced the auto makers to change their recommendations on oils and in turn had to force the oil producers to dramatically lower the levels of Zinc in the oils to solve the problem which they did. Now at this time about 2007 the Jeep 4.0 engine was not in production any longer and the Jeeps that were on the road had long since been properly broken in on the old high Zinc oil that was available in 2006 and earlier. Now comes all the engines that are being built in the performance aftermarket such as the Jeep 4.6 stroker engine which has a flat tappet camshaft. We have gone through a seminar with Joe Gibb s Racing Oils to get all of the information that you are reading in this article and have found by using their oil or at least a Zinc additive on the break in as well as all of the oil changes to come has almost eliminated premature camshaft wear on our Jeep 4.6 engines. So in close it is 100% mandatory to break your new Golen Jeep 4.6 engine in with a Zinc based oil and to run a Zinc based oil for the life of the engine.

8 Golens Engine Service General Jeep Information and Parts-Specifications This information is for your reference when replacing tune-up parts or maintaining your engine. If you have any other questions, please call the Golen Engine tech line. Break In Oil: Joe Gibb s BR Break In Oil or Royal Purple Break In Oil Oil: Joe Gibb s Hot Rod Oil or a Conventional name Brand 10/40 or 15/40 oil with a Zinc Additive Oil Filters: Name brand oil filter such as Napa or Wix (do not use Fram oil filters for we have found a problem with them collapsing internally and lowering the oil pressure) Fuel Injectors: 24 lb/hour Required Fuel: 91 or higher octane (based on (R+M)/2 method) Header: Aftermarket high-flow header Exhaust: Any good quality, free-flowing exhaust system Throttle Body: 62mm Throttle Body Spark Plugs: Champion RC9YC4 Spark Plug Gap:.035

9 Golens Engine Service LIMITED THREE YEAR LABOR WARRANTY Golen Engine Service (hereinafter referred to as GES ) warrants that their high performance engine shall be free of defects from workmanship, when installed properly by a competent technician used for normal street operation and serviced at proper intervals for a term of three years from the date of the purchase. GES will provide full labor repairs and replacement of all parts needed to repair your engine in the event of a problem upon start up. Inspection of the engine must be completed by GES to assure that the engine was not run longer than a few hours. If GES finds that the engine was run longer than a few hours the original Limited Three Year Labor Warranty will not apply. GES (under the Three Year Labor Warranty) will provide all repair, labor, inspection, machining and assembly at no cost to the original purchaser. The purchaser will be responsible for the cost of all parts needed to repair the engine under the Lifetime Labor Warranty. This warranty only covers the engine itself, at no time does this warranty or any other warranty given by GES cover the labor costs to remove or replace the engine from a vehicle or does it pay the labor costs of any mechanic. No exceptions. EXCLUSIONS and LIMITATIONS: This warranty does NOT cover damage or loss due to the following: 1. Misuse, maintenance neglect, abuse, vandalism, abnormal operation or accidents, not changing oil on time or not enough oil. 2. Defective or improper installation, Distributor not installed properly in turn melting pistons and rings or destroying bearings. 3. Improper break in: Camshaft wearing too soon, in turn ruining camshaft. 4. Environmental conditions, overheating, or freeze cracks: warped heads or cracks in head or block. 5. Over revving: bent or broken connecting rods, bent or broken push rods 6. Foreign material in combustion chamber or oil pan, bolts or nuts dropped into cylinder destroying pistons and valves. 7. Failure of components or parts not furnished or otherwise approved by GES for installation, or components or parts unsuitable for use with engine. 8. Damage to pistons and other components from detonation or preignition: distributor not installed properly, too much timing, bad fuel and not enough octane. 9. Crankshaft thrust surface worn: defective or improperly installed clutch, torque converter.

10 10. Internal modifications- any internal modifications will result in a warranty void. 11. Nitrous Oxide or Supercharger- installing these components on an engine that isn t properly set up for them will result in a void in warranty. Consult the GES Tech line if unsure. 12. Overfueling or other dilution lubrication: carb is too big or is out of adjustment. THIS WARRANTY DOES NOT COVER OR PROVIDE PAYMENT OR REIMBURSEMENT FOR THE FOLLOWING SERVICES: 1. Replacement of oil, anti freeze, or any other substance 2. Towing charges, vehicle rental, or other substitute transportation 3. Diagnostic time, labor to remove and/or reinstall engine, or service calls 4. Parts or items associated with warranted engine 5. Transportation or lodging 6. Loss of time, income, sales or profits, loss of use of vehicle 7. Lift, dock, or storage fees 8. Tune-ups or replacement of belts, hoses or maintenance items, routine, regularly required maintenance 9. Injury or death to persons or damage or destruction of property; consequential or incidental damages 10. Shipping warranted engine to and from GES CLAIM PROCEDURE: Immediately after the discovery of a potential defect the customer must comply with the following procedure: 1. Discontinue the use of the engine 2. Do not pull engine out of vehicle 3. Contact the sales person at GES that you originally purchased the engine from 4. Let GES help you figure out what is wrong with the engine (95% of the problems can be fixed with the help of the GES tech while the engine is still in the vehicle). 5. Unless a field repair is specifically authorized by GES, the engine or part thought to be defective must be returned to GES for evaluation. A copy of the customer s original invoice or receipt must accompany all returned engines or parts. 6. Returned engines must be returned with all parts intact that were originally furnished with the engine or charges will be made for the missing parts. 7. Disassembly of the engine by any parties other then GES will void the warranty unless it is specifically authorized by GES. BY PURCHASING THIS ENGINE FROM GOLEN ENGINE SERVICES IT IS UNDERSTOOD THAT THE CUSTOMER ACCEPTS AND AGRERES TO COMPLY WITH THE TERMS OF THE WARRANTY. A SIGNED COPY OF THIS WARRANTY MUST BE RETURNED WITHIN TEN DAYS OF

11 RECEIVING THE ENGINE. FAILURE TO DO SO WILL VOID ANY AND ALL WARRANTIES. BINDING ARBITRATION PLEASE READ THE FOLLOWING CAREFULLY, IT CONTAINS VERY IMPORTANT INFORMATION ABOUT YOUR RIGHTS AND OBLIGATIONS AS WELL AS LIMITATIONS AND EXCLUSIONS THAT MAY APPLY TO YOU. THIS DOCUMENT CONTAINS A DISPUTE RESOLUTION CLAUSE. Any claim against Golen Engine Service (hereinafter referred to as GES ) its agents, employees, successors, assigns, or affiliates arising from or relating to the purchase of parts or an engine this or this agreement, or it s interpretation or the breach, termination or validity thereof, the relationships which result from this agreement (including, to the full extent permitted by applicable law, relationships with third parties who are not signatories to this agreement), GES s advertising or any related purchase SHALL BE RESOLVED EXCLUSIVELY AND FINALLY BY BINDING ARBITRATION ADMINISTERED BY A STATE OR NATIONALLY RECOGNIZED ARBITRATION FIRM. The arbitration will be limited solely to the dispute or controversy between customer and GES. These terms and conditions apply (1) unless the customer has signed a separate purchase and sale agreement with GES, in which case the separate agreement shall govern, or (2) unless other standard GES terms apply to this transaction. FORUM SELECTION CLAUSE: It is agreed to by and between customer and GES that all disputes and matters whatsoever arising under, in connection with or without incident to this contract, warranty SHALL BE ARBITRATED EXCLUSIVELY IN AND BEFORE A COURT LOCATED IN THE STATE OF NEW HAMPSHIRE, TO THE EXCLUSION OF THE COURTS OF ANY OTHER STATE, TERRITORY, OR COUNTRY. This is enforceable on all contracts regardless to where product has been shipped. Customer hereby waives any venue or other objection that he may have to any such action or proceeding being brought in any court located in the State of New Hampshire. If either party is to institute or commence litigation in any venue or format other than that specified above, specifically binding arbitration in New Hampshire it shall be liable to the other for all costs, expenses, and attorney fees associated with that action.