Engine out
 

http://i21.photobucket.com/albums/b2...ps85f0ab26.jpg

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Engine install
 

http://i21.photobucket.com/albums/b2...pse81bab30.jpg

http://i21.photobucket.com/albums/b2...ps8609dbd4.jpg

http://i21.photobucket.com/albums/b2...ps5691b93b.jpg

http://i21.photobucket.com/albums/b2...ps8b88eeeb.jpg

http://i21.photobucket.com/albums/b2...ps38351df5.jpg

http://i21.photobucket.com/albums/b2...psbbb1d265.jpg


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oof. be sure and put in the starter before you hook up the oil cooler lines!

Resurface exhaust manifold
 

http://i21.photobucket.com/albums/b2...ps4d0b2d1b.jpg

http://i21.photobucket.com/albums/b2...psec038969.jpg

http://i21.photobucket.com/albums/b2...ps30acdfca.jpg

http://i21.photobucket.com/albums/b2...psc9f7e157.jpg

http://i21.photobucket.com/albums/b2...ps8b828c2e.jpg

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Nice! Send that puppy out for some Jet-Hot coating while you're at it! :D :D

Like these:

http://www.w124performance.com/image...t/Jet-Hot1.jpg

http://www.w124performance.com/image...t/Jet-Hot2.jpg

Yes
 

The starter is in.

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Exhaust manifold Gasket
 

1992 OM602 exhaust manifold Gasket.

This shows the MASSIVE exhaust gas leak at both ends of the gasket = On a turbo engine this directly equates to Power loss.
1992 OM602 Exhaust Manifold Gasket Photos by whunter | Photobucket


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Special tool for running your diesel engine without the Turbo installed
 

http://www.peachparts.com/shopforum/diesel-discussion/348079-special-tool-running-your-diesel-engine-without-turbo-installed.html#post3259412

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Done
 

Here are a couple of the last pictures before it went home..

I will note that the replacement engine has no detectable blow-by, and seems to be (as claimed) a 140K mile engine.

The only parts moved from the junk engine:
* Oil level sensor, (electrical pin damaged in shipping).
* New vacuum pump.

Special observation for anyone facing this job....................................
#1. Remove the turbo and exhaust manifold BEFORE you start pulling the engine (it was much easier for me with head and oil filter housing removed)...
#2. BEFORE installing the donor engine, Remove the turbo and exhaust manifold...
#3. Change the oil and filter, pre-soak the filter before installing.
#4. Wire down the shutoff lever...
#5. Blank off the turbo oil feed and use the starter to build full 3-bar oil pressure (to minimize engine wear and avoid turbo damage).
#6. Release the shutoff lever...
#7. Start and run the engine with the turbo oil feed Blank off installed (to stabilize the oil and fuel system, verify engine condition and avoid turbo damage).
#8. Remove the turbo oil feed Blank off...
#9. Pre-lube the turbo = oil feed side, you want to see drips coming out the drain port.
#10. Install the turbo.

This shows the MASSIVE exhaust gas leak at both ends of the gasket = On a turbo engine this directly equates to Power loss.
1992 OM602 Exhaust Manifold Gasket Photos by whunter | Photobucket


http://i21.photobucket.com/albums/b2...ps8b930d9b.jpg

http://i21.photobucket.com/albums/b2...ps5705c787.jpg

http://i21.photobucket.com/albums/b2...ps24521931.jpg

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