Re-Fitting Reconditioned Engine

Remove engine.
Information
- Some modifications are required in order to replace the old, removed engine with a new one.
- Starting point for conversion work: Old engine is secured to assembly support and the new one is in the transport cradle.
- At higher mileages, components (coolant hoses, clips, etc.) must be checked for damage and replaced if necessary.
- Seals must be checked and replaced if necessary.
Remove engine from transmission. → Removing Engine From Transmission
Remove numerous transport stoppers on water and vacuum connection pieces on the new engine.
Re-fit numerous cable clips.
Re-fit coolant hoses.
1. 5.1. Re-fit the two front coolant hoses leading to the radiator. →
  
  Fig 1: Identifying Coolant Hoses
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2. 5.2. Re-fit the rear coolant hoses between the engine and coolant reservoir.
  →
  
  Fig 2: Identifying Coolant Hoses And Reservoir
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3. 5.3. Re-fit the two coolant hoses between the engine and transmission. →
  
  Fig 3: Identifying Coolant Hoses And Clamps
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Re-fit crash panel for high-pressure pump. -arrows-

Fig 4: Locating Crash Panel With Engine Removed
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Turbo: Re-fit connecting hose on PCV line. -Schlauch-

Fig 5: Identifying PCV Hose
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Turbo: Re-fit right boost pressure pipe → Re-fit short tube on the left-hand side. →

Fig 6: Identifying Right Boost Pressure Pipe
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Fig 7: Connecting Tube For Ventilation
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Turbo: Re-fit right holder for primary catalytic converter -9- .

Fig 8: Exploded View Of Holder For Catalytic Converter - Turbo Engine
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Re-fit design cover on bar ignition modules. For details, see → 108319 REMOVING AND INSTALLING ENGINE COVER (DESIGN COVER) ON DFI ENGINES
Remove drive belt. Fit sheetmetal holder between timing-case cover and coolant hose. For details, see → WM 137819 REMOVING AND INSTALLING DRIVE BELT ON 4.8 L DFI ENGINE
Re-fit air-conditioning compressor. For details, see → Installing Air Conditioning Compressor
Re-fit tandem pump or power-steering pump.
1. 13.1. Counter pulley with belt holder and remove pulley. →
  
  Fig 9: Removing Pulley Using Tool
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2. 13.2. Remove feed lines on cylinder head. -arrow-
  
  Fig 10: Locating Feed Lines
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3. 13.3. Remove fastening screws on tandem pump or power-steering pump (three screws at the front -arrows- , one screw at the back -arrow- ).
  
  Fig 11: Locating Mounting For Front Tandem Pump
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  Fig 12: Locating Mounting For Rear Tandem Pump
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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
Move upper ATF line into installation position (feed it in).
Re-fit vacuum line, depending on equipment. →

Fig 13: Locating Vacuum Line
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Re-fit ground cable under the generator. →

Fig 14: Locating Ground Cable
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V8 naturally aspirated engine: Re-fit heat protection panels on both exhaust manifolds and on the generator. -arrows-

Fig 15: Locating Heat Protection Panels On V8 Naturally Aspirated Engine
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Re-fit drive plate or flywheel.
Check that you have not forgotten any parts.
Mount engine on transmission. → Mounting Engine On Transmission
Install engine.