STANDARD INSTALLATION PROCEDURES
(NEW & REMANUFACTURED ENGINES)
Service Parts Operations Installation Instructions
General Motors Corporation GOODWRENCH
Engineering Department REMANUFACTURED ENGINES
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
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
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.
This engine has been remanufactured subsequent to the model year of the vehicle
and as such may contain design refinements not included in original service
information, i.e. 1989 engines may incorporate design features normally in newer
models. If future service is necessary for this engine in addition to the service
manual, consult GM Parts Catalogs, GM Parts and Accessories Information Bulletins
and Dealer Service Bulletins for proper service parts and service procedures
necessary to accommodate these revisions.
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 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:
CORE RETURN PROCEDURE: The ENGINE CORE MUST BE
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!!!
WARRANTY: Where applicable, fill in and return the WARRANTY CARD. This greatly
aids the remanufacturer in identifying non-conforming worn or damaged parts.
Detailed warranty information is a necessary tool in developing design and manufacturing