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STANDARD INSTALLATION
PROCEDURES
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(NEW &
REMANUFACTURED ENGINES)
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| Service
Parts Operations |
Installation
Instructions |
| General Motors
Corporation |
GOODWRENCH |
| Engineering Department |
REMANUFACTURED
ENGINES |
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| 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. |
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| 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. |
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THE
USE OF SURFACE CONDITIONING DISCS IS STRICTLY FORBIDDEN, |
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i.e.,
SCOTCH BRITE,™ ROLO BRISTLE DISCS,™ Soc Att,™ ABRASIVE DISCS. |
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| 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. |
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| 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. |
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| 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). |
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| 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. |
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| 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. |
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| 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. |
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| 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. |
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| 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). |
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| For
subsequent service, refer to the manufacturer's recommended intervals:
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CORE
RETURN PROCEDURE: The ENGINE CORE MUST BE |
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RETURNED
IN ORIGINAL PACKAGING |
WITH
SAME CONTENT AS REPLACEMENT ENGINE |
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DRAIN THE ENGINE OIL!
DRAIN THE COOLANT! |
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FAILURE TO DO SO MAY REDUCE
CORE CREDIT!!! |
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| 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 refinements. |
