100431 Re-fitting reconditioned DFI engine

WM 100431 Re-fitting reconditioned DFI engine

Re-fitting reconditioned engine

1. Remove engine.

Information

- Some modifications are required in order to replace the old, removed engine with a new 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.

2. Remove engine from transmission. -> 100127 Removing engine from transmission and mounting engine on transmission - section on "Removing" 100127 Removing engine from transmission and mounting engine on transmission
3. Remove numerous transport stoppers on water and vacuum connection pieces on the new engine.
4. Re-fit numerous cable clips.
5. Re-fit coolant hoses.
5.1. Re-fit the two front coolant hoses leading to the radiator. => Coolant hoses to radiator





Coolant hoses to radiator

5.2. Re-fit the rear coolant hoses between the engine and coolant reservoir. => Coolant hoses to reservoir





Coolant hoses to reservoir

5.3. Re-fit the two coolant hoses between the engine and transmission. => Coolant hoses => Coolant hoses to reservoir





Coolant hoses

6. Re-fit crash panel for high-pressure pump. -arrows-





Crash panel with engine removed

7. Turbo: Re-fit connecting hose on PCV line. -Hose-





PCV hose

8. Turbo: Re-fit right boost pressure pipe => Right boost pressure pipe. Re-fit short tube on the left-hand side. => Connecting tube for ventilation





Right boost pressure pipe





Connecting tube for ventilation

9. Turbo: Re-fit right holder for primary catalytic converter -9-.





Holder for catalytic converter - Turbo engine

10. Re-fit design cover on bar ignition modules. For details, see -> 108319 Removing and installing engine cover (design cover) on DFI engines 108319 Removing and installing engine cover (design cover) on DFI engines
11. Remove drive belt. Fit sheetmetal holder between timing-case cover and coolant hose. For details, see -> 137819 Removing and installing drive belt on 4.8-litre DFI engines 137819 Removing and installing drive belt on 4.8 l DFI engine
12. Re-fit air-conditioning compressor. For details, see -> 873419 Removing and installing air conditioning compressor - section on "Installing" Service and Repair
13. Re-fit tandem pump or power-steering pump.
13.1. Counter pulley with belt holder and remove pulley. => Countering pulley





Countering pulley

13.2. Remove feed lines on cylinder head. -arrow-





Feed lines

13.3. Remove fastening screws on tandem pump or power-steering pump (three screws at the front -arrows- , one screw at the back -arrow- ).





Mounting for front tandem pump





Mounting for rear tandem pump

14. Remove engine carrier and fit it onto the transmission later after you have mounted the engine. -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing engine from transmission and mounting engine on transmission
15. Move upper ATF line into installation position (feed it in).
16. Re-fit vacuum line, depending on equipment. => Vacuum line





Vacuum line

17. Re-fit ground cable under the generator. => Ground cable





Ground cable

18. V8 naturally aspirated engine: Re-fit heat protection panels on both exhaust manifolds and on the generator. -arrows-





Heat protection panels on V8 naturally aspirated engine

19. Re-fit drive plate or flywheel.
20. Check that you have not forgotten any parts.
21. Mount engine on transmission. -> 100127 Removing engine from transmission and mounting engine on transmission - section on "Mounting" 100127 Removing engine from transmission and mounting engine on transmission
22. Install engine.