Engine Installation Instructions

Engine installation is a technically demanding process that requires strict adherence to correct procedures and manufacturer specifications. At Motorlager, we provide every customer with the necessary documentation and guidance — and we ask that these instructions be read carefully and passed on to the responsible mechanic before installation begins.

A copy of the engine installation manual is included with every engine we supply.

⚠️ Please note:
In accordance with Motorlager's warranty terms, the engine must be installed in full compliance with the manufacturer's requirements and recommendations. Motorlager accepts no responsibility for engine damage resulting from improper installation.

Before fitting the new engine, the following checks must be completed without exception:

Before installing a new engine, determine why the original engine failed. Was it a crankshaft fault? Turbocharger failure? A fuel system malfunction? Identifying and resolving the root cause is essential — fitting a new engine without addressing the underlying problem risks repeating the same failure.

Upon delivery, inspect the engine carefully for any visible damage that may have occurred during transportation. Any concerns should be reported to us immediately before installation proceeds.

Ensure all rubber and metal gaskets are in place and in good condition. Do not use engine silicone in areas where it is not intended. Always use the correct, appropriate gaskets — no substitutes.

All rubber connections, hoses, and wiring must be properly connected, undamaged, and free from any makeshift repairs or adhesive fixes.

Inspect the intercooler radiator and all associated hoses. Confirm the radiator is free from punctures and that there is no grease or oil residue inside it.

Check the water pump for condition and functionality before installation. Replace if there is any doubt about its serviceability.

Verify that all fuel injectors are functioning correctly. A faulty injector can cause serious piston damage in a new engine.

Always replace the oil cooler. In most cases it will be partially or fully blocked — a clogged oil cooler is a common cause of engine damage and must not be reused.

We strongly recommend fitting a new thermostat alongside the new engine. If reusing the existing unit, verify that it is functioning correctly before installation.

Check that neither the DPF (diesel particulate filter) nor the catalytic converter is blocked. A restriction in the exhaust system will force exhaust gases back into the engine, damaging the turbocharger and the new engine.

Check that the vacuum pump operates freely and rotates without resistance. Replace with a new unit if there is any sign of damage or stiffness.

Install the engine's main timing belt or chain using the correct specialist tools. Incorrect timing installation is one of the most critical and common causes of immediate engine failure.

Check or replace the oil level sensor. An ageing sensor may fail to read correctly or provide false readings, which can result in undetected oil loss.

Verify that the crankshaft position sensor is in good condition and correctly secured in position.

Inspect the flywheel before installation. A worn or damaged flywheel can produce noise immediately upon starting the engine and may cause further complications if not addressed.

To protect the new engine and maintain warranty validity, we recommend replacing the following components as a matter of course:

• Engine oil

• Air, oil, and fuel filters

• Spark plugs (or glow plugs for diesel engines)

• Fuel injector seals

• All gaskets used to connect ancillary components (turbochargers, compressors, intake/exhaust manifolds, fuel pump, etc.)

• Oil cooler

• Thermostat

Once the engine has been installed, carry out the following before starting:

1. Verify that ignition timing is correctly set.

2. Check engine oil and coolant levels.

3. ⚠️ Critical: Before starting the engine, confirm that the entire lubrication system is filled with oil.

4. Disconnect the fuel supply relay before the first start. Crank the engine through several full rotations to prime the oil filter and ensure oil pressure is established before combustion begins.

Throughout the installation process, the mechanic must take a minimum of three photographs documenting the installation progress and its completion.

These photos must be sent to: warranty@motorlager.eu

Failure to submit the required photographs will void the warranty.

The following actions will result in immediate warranty voidance:

• Installation photos not submitted to warranty@motorlager.eu

• Failure to follow Motorlager's installation instructions and recommendations

• Engine tuning, remapping, or any modification that alters engine output

• Engine seals opened or damaged without prior authorisation from Motorlager

If you have any questions about the installation process or your warranty, please don't hesitate to contact us.

📧 Email: info@motorlager.eu
🕐 Monday – Friday, 07:00–16:00

We hope for your full cooperation — clear communication and careful installation are the best foundation for a long-lasting, trouble-free engine.