Engine Installation Instructions

Installation Instructions

Attention: The Technician must identify and repair the problem(s) that caused the original Engine replacement, or additional Engine failures not covered under Warranty may occur. Diagnosis of Proper operation of the FUEL, LUBRICATION, COOLING, IGNITION, INDUCTION, EXHAUST, E.G.R., VACUUM and ELECTRICAL SYSTEMS is mandatory.

WARNING: When cleaning Gasket Sealing Surfaces on the REMANUFACTURED Engines and/or Cleaning Parts from the Failed Engine to be reused, the use of SURFACE CONDITIONING DISCS that contain abrasives such as ALUMINUM OXIDE may cause Infant Bearing Failure.

THE USE OF SURFACE CONDITIONING DISCS IS STRICTLY FORBIDDEN, i.e., SCOTCH BRITE,™ ROLO BRISTLE DISCS,™ Soc Att,™ ABRASIVE DISCS.

If the original Engine failed either catastrophically or due to Bearing Failure, the Engine Oil Cooler must be replaced, if the vehicle is so equipped, and the Oil Lines must be removed from the vehicle and thoroughly flushed or replaced. Warranty Data shows that more than half of all warranty claims for infant failures are associated with lack of proper Lubrication.

ENGINE INSTALLATION: Before installing this engine, verify that you have the correct engine for your application. Refer to the appropriate Vehicle Chassis Service Manual for proper repair procedures and specifications (i.e. fastener torque, torque sequencing, ignition timing, valve adjustments, coolant fill, air purge and fluid volumes).

1. Seals, Gaskets & Components: After removing the old engine, use new seals, gaskets, oil pump, filters (oil, air, fuel) and spark plugs. Transfer all necessary components to the replacement service engine. Prior to transferring, thoroughly clean and inspect or replace all parts you will be transferring such as the Oil Pan, Intake Manifold, Front Cover, Valve Covers, Distributor Assemble, Ignition Wires, Harmonic Balancer front oil seal surface, Oil Filter Adapter and Lines, Oil Pick-Up Tube, and Fuel System. (This will avoid possible contamination or installation of worn or damaged parts and/or less than normal performance that could damage the service engine). On vehicles where the engine has been damaged due to overheating, check and recondition or replace the Radiator, Radiator Cap, Water Pump, Coolant Hoses, Thermostat, Fan Clutch and Cooling Fan Sensors, Always add Cooling System Tabs. Cooling System Tabs aid in sealing porosity in aluminum and remove silicates from the Water Pump Shaft that form from the coolant, to Extend Water Pump Seal life.

2. Pre-Lube: For applications that do not get shipped with sheet metal: Prior to installing the oil pan and with the engine upside down on an engine stand, pour ¼ can of GM ENGINE OIL SUPPLEMENT (GM P.N. 1052367) over the crank and bearing cap assemblies. Fill the oil pump prior to installation. Install the oil pan and rotate the engine on the engine stand right side up. Pour the rest of the E.O.S. over the rocker Assemblies and cam shaft assembly subsequent to installing the intake and rocker covers. After installing the engine in the vehicle, add an API Certified Engine Oil. Refer to your service manual for the proper grade, volume, and seasonal viscosity.

3. Oil Pump Prime Procedure: Where applicable use a drill motor attached to the oil pump through the distributor hole. Turn the oil pump at 200 to 500 rpm for an additional two minutes after the normal oil pressure is achieved. This is to flush any debris from the engine without a load on the crank bearings while maximum bearing clearances are present. Coat the Distributor gear with E.O.S. subsequent to Distributor installation. For applications without distributor drive-type oil pump, use a Pressure Pre-Luber following the manufacturer's recommendations. As a last resort, only when the above mentioned methods are not available crank the engine for two minutes after oil pressure is reached. Disable the Spark and Fuel while cranking the engine during this pre-Lube procedure to prevent cylinder wall washdown. Check the oil level and fill to the proper level.

4. Engine Break-In: This assembly has been tested and can be driven without a formal "break-in" schedule. However after performing steps 1, 2 and 3, start the engine and let it idle at 1600 to 2000 RPM for 10 to 20 minutes allowing the oil pressure and temperature to stabilize. Refer to the service manual for the proper pressure range. During this time, where applicable, adjust the timing and valve clearance and check for leaks. ROAD TEST the vehicle for a minimum of 10 miles (16.09 km for Canada) with combined city and highway driving, do not exceed 50 miles per hour (80 kph for Canada), or use any fast throttle responses. Send the vehicle to be cleaned prior to returning to the customer.

Instruct customer that the first service interval for changing oil and filter should be between 300 to 500 miles (500 km to 800 km for Canada).

For subsequent service, refer to the manufacturer's recommended intervals:

RETURNED IN ORIGINAL PACKAGING
WITH SAME CONTENT AS REPLACEMENT ENGINE

DRAIN THE ENGINE OIL! DRAIN THE COOLANT!

FAILURE TO DO SO MAY REDUCE CORE CREDIT!!!