Re-Fitting Reconditioned Engine

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

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.