so, part one http://www.fordownersclub.com/forums/topic/39262-16-tdci-knocking-on-revs/

Long story short, atleast 2 decided to take a hike (havent checked what the intake side looks), so ive got atleast few bended valves, busted exhaust cam, and it looks like i need to replace nearly every cam follower...

So, the only chanse realy is change eather the whole head, or the whole engine.

First of, has anyone ever took an engine of from one of these? Is it easyer to take out whit trans still engaged, or is it easyer first take off the trans, and then the engine? And on witch way does it come out easyer, above or down under?

Second one is about the replacement engine... For some wierd reason, the 1.6 TDCi seems to be made out of pure gold... atleast according to the price. Cant find any 1.6 tdci's under 1600£ when you can get mondeo 2L duratorq for 400£... ?! Witch got me into thinking, how big pain in the ass would it be to put something else in there ? For examle if i go for 1.8 TDCi ?

As far as I understand, the trans needs to be disconnected and then the engine should come out top way easier.

The size of the engine is going to be a right nightmare, for example, the bonnet layout in a 1.6 can differ slightly, but enough against a 1.8, take a look at your owners manual and you should see what I mean, each one has a few tweaks to accomodate the engine size, so you might start with a slightly bigger engine, but need to move a few other bits...

the 1.6 is a good engine, but because it has to accomodate also the Euro 4 compliancy of the DPF, then its a bit more expensive than the 1.8 as you have seen...

[quote name='jeebowhite' timestamp='1359219359' post='230475']
As far as I understand, the trans needs to be disconnected and then the engine should come out top way easier.

The size of the engine is going to be a right nightmare, for example, the bonnet layout in a 1.6 can differ slightly, but enough against a 1.8, take a look at your owners manual and you should see what I mean, each one has a few tweaks to accomodate the engine size, so you might start with a slightly bigger engine, but need to move a few other bits...

the 1.6 is a good engine, but because it has to accomodate also the Euro 4 compliancy of the DPF, then its a bit more expensive than the 1.8 as you have seen...
[/quote]

Thanks, il guess i stick whit the 1.6l... too bad the price is bit salty.

Btw, is there anyway to block the EGR whitout causing any DTCs? On mondeo you could just make a cover plate over the EGR connection at the exhausmanifold, but does the focus PCM monitor the airflow in the egr? Or would it be possible to rip the whole egr out, and plugin a dummy resistor to fool the PCM?

Litle bump / update.

I bought "new" engine just few days ago, 1.6 TDCi, from a -06 donor, 5k miles driven. Now, im planing to do the engine swap next weekend (being pessimist i took vacation from work for friday and monday ). But, the main question is, what is the most idealistic way to take the engine off? Lift only the engine off, drop the engine and transmission down, lift the whole package out?

This is bit crusial, since depending the remove method, i need to choose if i do the job at my fathers garage (that has propper 4 pillar lift) or at my brothers garage (that has only "belly lift" that is used for tire change but has better inventory of tools, and most of all, a highpreasure diesel powered steam cleaner to clean the engine bay )

I did some googling according this, but i cant realy make my mind. Some say that you can de-couple the engine from the transmission inside the engine bay, and just lift the old engine out, and some say you need to drop the whole subframe down, and pull it off. :/

subframe down gearbox out then engine out through the top then youll need to be care full to support the subframe to prevent distortion

i think on the mk2 both the engine and gearbox can come out the top. if not the gearbox can be removed without touching the subframe

never changed an engine in a mk2 but i have done a few swaps in other cars now

i dont know how things are in Finland but over here you need to complete forms for the DVLA to say you have changed the engine and the new number etc.

[quote name='stef123' timestamp='1360450699' post='234549']
i think on the mk2 both the engine and gearbox can come out the top. if not the gearbox can be removed without touching the subframe

never changed an engine in a mk2 but i have done a few swaps in other cars now

i dont know how things are in Finland but over here you need to complete forms for the DVLA to say you have changed the engine and the new number etc.
[/quote]


same problem here, all the previous engines ive pulled out were rear wheel drive, so pretty much just remove the drive shaft, and all the hoses / wires and lift the whole package out

Im looking the easyest way, i dont realy need to wory about wheel allignment, since my dad's garage has machine to adjust them back. Thats what made me wonder would it be possible to drop unbolt the front shocks, drop the whole front subframe whit the engine, and "roll" it out ? Or can you lift the whole package out. Found one "tutorial" where they lowered the subframe inorder to get clearance to de-couple engine from trans, then leave trans on supports, and lift the engine out.

After that wound one where everything came nicely out of top, and one where everything came off from the bottom :/



For the DVLA, they should not be intereseted since the swap is from 1.6tdci -> 1.6tdci... If you change the engine to different type / more powerfull one, then they give you the hell

all i know is to do a clutch on the mk2 the dealers have to drop the subframe as theres not enough clearance otherwise

Well, i got the engine changed. Took me ~6h to drop the engine, and ~4h to put the new one back.

Just in case someone else needs to do it, it comes out realy easy from the bellow.

Unfix the turbo, exhaust manifold, first part of the exhaust, boost pipes, alternator and AC pump. Disconnect the wiring harness from the engine, gearbox cables, clutch pipe and the cooling hoses. Remove drive shafts and the "drag bar" under the car.

Now just support the engine by some sort of lift, unfix the engine mounts, and it comes straight down Its actualy realy easy to do.