Additional Installation Instructions

INSTALLATION REQUIREMENTS AND RECOMMENDATIONS Your engine has been remanufactured by precision workmen to rigid specifications and tolerances, using quality replacement parts. By following the steps outlined in this limited warranty, you can ensure your engine a longer, trouble-free life and protect your warranty.

STEP ONE: SELECTING YOUR INSTALLER This engine has been carefully remanufactured to precision standards. If certain steps are taken by the person making the installation, it will perform properly.

An engine is a complex component that requires a high degree of technical knowledge to install. Before an engine can be properly installed, it is recommended that the installer be ASE certified or have equivalent credentials.

If a properly remanufactured engine fails to perform satisfactorily, it can be due to detonation, preignition or “lugging,” overheating or excessively rich air-fuel ratio, under-lubrication, dirt, coolant seepage, or ineffective air filtering. The above-mentioned reasons for failure are under the control of the installing mechanic/technician, and are not the responsibility of the engine remanufacturer.

Another important factor is that your installers have the proper engine diagnostic equipment. Be certain the equipment is capable of diagnosing emissions, ignition, fuel systems and in-vehicle computers and sensors.

CAUTION: This partial list of recommended installation procedures and instructions are intended only as a guide. If you are not qualified to perform an installation, do not attempt it, as you may be liable for resulting engine failure.

To avoid harmful contamination, thoroughly clean parts that will be attached to the rebuilt/remanufactured engine. Also, any and all parts not included with a remanufactured engine or engine component should be cleaned properly before installing on a new remanufactured engine.

Vehicle computers and the fuel injection system must be recalibrated for the replacement engine. It is essential this be checked. Not doing this alone can cause your engine to fail. Look for a clean work environment at your installer. Cleanliness is essential in an engine installation. Neat and orderly shops often produce the best workmanship.

STEP TWO: REPLACING YOUR ENGINE

• Check for freight damage or dirt contamination, which could occur during shipping.
• Check application of product. Make sure the mounting holes, bell housing, crankshaft snout, flywheel mounting flange, bolt hole patterns, pilot shaft hole, smog/non-smog application, etc., are the same on new products as the old.
• Clean all accessories to be transferred to the new product from the old one. Be certain the intake manifold is straight and not warped.

Other procedures may be necessary to ensure proper engine operations.

Other operating systems in your vehicle may need to be checked, particularly if they may have been responsible for or contributed to the failure of the original engine.

The radiator may need replacing and/or cleaning. Air-filtering systems, pollution control components, sensors, injectors, and vacuum-operated devices may need attention as well as oil coolers.

Rely on your installer for advice on these items. They have the expertise and equipment to properly diagnose and will do so as a matter of procedure. Do not take short cuts, as it will only cause greater expense and inconvenience in the future.

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 will 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.  You should replace all O2 sensors and drain the exhaust system of all excessive antifreeze, water and oil that was burned previously and is now condensed back into the exhaust system.  Not doing this will cause you to have abnormal combusting temperatures in your cylinders causing overheating, melting heat tabs, damaging heads, head gaskets and pistons, along with other things associated with elevated temperatures.

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.  (Always make sure you have distributor in 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 wash down. Check the oil level and fill to the proper level.  If proper priming is not done, you will scar and damage the cam bearings causing knocking and or loss of oil pressure.

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.

STEP THREE: REPLACING PARTS Replace recommended parts, and then follow up with your installer to thoroughly check other parts, which may have contributed to the original failure.

Your remanufactured engine should begin operation under the same conditions as the original engine. It is recommended that the below listed parts be replaced.

Spark Plugs, Thermostat, Crankcase Inlet Filter, Air Filter, PCV Valve, Fuel Pump, Fuel Filter, Oil Filter, Oil Sending Unit, Pick-up Screen, Lifters

It is highly recommended that you replace or thoroughly test and inspect the following parts.

Carburetor, Distributor, Harmonic Balancer (Sleeve), Water Pump, All Belts, Radiator Cap, High Tension Wires, Map Sensors, All Hoses, Oxygen/Temperature Sensors, Injectors, Throttle Position Sensors

Now is the easiest time to replace these parts. If these replacements are performed now, future labor expenses and inconvenience will be avoided.

STEP FOUR: CHECK-UP SHave engine analyzed on an engine diagnostic scope before leaving the shop.

For the first 200-300 miles, avoid sustained high-speed driving or carrying of loads.

A check up is required after the first 500 miles to protect your warranty. At this time check ignition timing, change oil and filter, adjust the carburetor and idle speed, inspect for oil and water leaks, and check the general operation of the engine. Check up costs is the responsibility of the vehicle owner.

STEP FIVE: MAINTAINING AT REGULAR INTERVALS Perform routine maintenance on your vehicle on a consistent basis. Your warranty requires the below items to be performed for Basic Engine Maintenance.

• Change oil and filter every 3 months or 3,000 miles. Do not use synthetic oil for the first 5,000 miles. For gasoline engines use SG rated oil.
• Check fluid levels every gas fill up.
• Change air filters every 25,000 (more often in a dusty environment).
• Check belts/hoses at 30,000-mile intervals.
• Tune-up, including spark plug replacement every 25,000 miles.

Keep all maintenance records. We recommend that you keep all receipts and accurate records for maintenance work performed on your vehicle. In order to have repairs made under warranty, we require documentation of proper vehicle maintenance as outlined in Factory Warranty and Vehicle Owner’s Manual as well as the steps outlined in Step Four above.

STEP SIX: WARRANTY REGISTRATION Return your completed warranty registration, which is provided with your engine, to the factory within ten days of installation. Read and make certain you understand the terms and conditions of your warranty.

QUESTIONS Please call your Customer Service Department with any questions or concerns you may have. Our number is: ( 773) 586-3577.