Re-Fitting Reconditioned Engine

Re-fitting reconditioned DFI engine





Re-fitting reconditioned engine

1. Remove engine.
2. Remove engine from transmission.

Information:
^ Some modifications are required in order to replace the old, removed engine with anew one.
^ Starting point for re-fitting work: Old engine is secured to assembly support and the new one is in the transport cradle.
^ At higher mileages, components (cooling hoses, clips, etc.) must be checked for damage and replaced if necessary.
^ Seals must be checked and replaced if necessary.

3. Disconnect coolant hoses.
Remove transport stoppers on water and vacuum connection pieces on new engine. Re-fit clip on cable guide.
4. Re-fit additional coolant pump with holder. -> Tightening torque: 10 Nm (7.5 ftlb.)





Removing and installing additional coolant pump

5. Re-fit tank vent with lines on sheet metal holder.
6. Re-fit auxiliary units and bracket for auxiliary units. Screw M8 x 40 -> Tightening torque: 25 Nm (19 ftlb.) screw M8 x 8, 992 x 28 -> Tightening torque: 25 Nm (19 ftlb.)





Removing and installing auxiliary units and bracket for auxiliary units

6.1. Re-fit generator.
6.2. Re-fit right engine bracket. -> Fastening screws -> Tightening torque: 45 Nm (33 ftlb.)





Fastening screws

6.3. Re-fit belt tensioner.
7. Re-fit coolant hoses.





Coolant hoses

8. Pre-fit heat protection. -1-





Heat protection on cable

9. Re-fit ground cable to body on engine.
10. Check that you have not forgotten any parts.
11. Mount engine on transmission.
12. Install engine.