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engine removal guide

Transit Mk6 & Mk7 Forum. All Transits 2000 - 2013

engine removal guide

Postby scas » Thu May 25, 2017 12:02 pm

hi, ive had a quick look but couldnt find anything. im looking for a step by step guide to remove and replace an engine in a 2.4 di transit. obviously the front end off 1st, but whats next, what can i leave on and what needs to come off. thanks
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
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Re: engine removal guide

Postby KevofCov » Thu May 25, 2017 8:51 pm

Yep me too - including the problem of having different keys
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Re: engine removal guide

Postby scas » Fri May 26, 2017 4:53 pm

KevofCov wrote:Yep me too - including the problem of having different keys

if you use original ecu and just virginise the pump that comes with new (to me ) engine then you can still have your original keys
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
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Re: engine removal guide

Postby v8dave » Fri May 26, 2017 9:44 pm

2.4 di is presumably mk6

here

and in case anyone searches, the mk7 is here
mk7 08reg 2.4 T350 LWB MHR RWD
mk6 X reg 2.4 T350 LWB MHR RWD - scrapped
mk4 J reg 2.5 L300 LWB MHR RWD - sold on

Notice a trend there ? not too big and not too small
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Re: engine removal guide

Postby scas » Sat May 27, 2017 9:30 am

the trouble with going by ford is that they tell you to take all the ancillaries off, which im pretty sure they dont need to be removed, but thanks
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Re: engine removal guide

Postby scas » Sat May 27, 2017 9:39 am

so heres what i think happens-bonnet off, bumper, headlights, slam panel, condenser, bumper beam,radiator off. disconnect airbox to turbo, turbo to intercooler, intercooler to egr. manifold to exhaust 4 bolts. heater matrix pipes, vacuum tube to brake, power steering hoses, thermostat to expansion tank hose, and various electrical connectors. also starter motor and the engine mounts and the bell housing.
after that what else? also i did the clutch in my daughters stilo and it took me 45 minutes to find a hidden bolt on the bell housing-are there any on an mt75?


any help would be appreciated
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Re: engine removal guide

Postby v8dave » Sat May 27, 2017 11:25 am

scas wrote: i did the clutch in my daughters stilo and it took me 45 minutes to find a hidden bolt on the bell housing-are there any on an mt75?

Well, reading the ford instructions would at least give you a clue as to whether that sort of problem exists.
mk7 08reg 2.4 T350 LWB MHR RWD
mk6 X reg 2.4 T350 LWB MHR RWD - scrapped
mk4 J reg 2.5 L300 LWB MHR RWD - sold on

Notice a trend there ? not too big and not too small
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Re: engine removal guide

Postby scas » Sat May 27, 2017 12:05 pm

true, could you post a link to the removal guide in the ford workshop manual-i cant seem to find it in your link-thanks
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Re: engine removal guide

Postby v8dave » Sat May 27, 2017 2:05 pm

Engine removal for a mk6 2.4 di

here

The menu structure on that website is a bit odd compared to the original etis setup.
mk7 08reg 2.4 T350 LWB MHR RWD
mk6 X reg 2.4 T350 LWB MHR RWD - scrapped
mk4 J reg 2.5 L300 LWB MHR RWD - sold on

Notice a trend there ? not too big and not too small
User avatar
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Re: engine removal guide

Postby scas » Sat May 27, 2017 4:07 pm

thanks, i can see all the bolts for the bell housing
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Re: engine removal guide

Postby toppetsaha » Sun May 28, 2017 1:42 pm

Done this last week..

Just a few tips that helped me:

along with the front end, remove the wiper arms & windscreen drain panel.

I think there are around 3 bolts at the top of the bell housing hidden right at the top

Get the engine crane as close as possible to the cam cover when tying it on.

Remove old engine with the subframe attached, remove subrame from old engine when out & dismantle, attach the engine mounts onto the new engine first, then fix the subrame to them. The subrame only goes one way around.

Attach the gear box to the engine before attaching the subrame to the chassis.

The pipe on the back of the vacuum pump is a right pain in the arse to get to, make sure this is one of the first things that is connected.

I used a jack under the sump aswell as the crane to get the engine lined up to the gear box, i didn't need to loosen up the gear box mount.

The speedo/crank sensor plugs can be confused, if they are in the wrong sockets the engine will start but wont run. if that makes sense!

Hope this helps

It is a pretty easy job, with my limited knowledge i managed to do an engine/ecu swap & clutch & flywheel replacement in 19 hours.
MK1 - Camper project
MK6 2.4 75ps
MK7 2.4 100ps
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Re: engine removal guide

Postby scas » Sun May 28, 2017 3:06 pm

Done this last week..

Just a few tips that helped me:

along with the front end, remove the wiper arms & windscreen drain panel.

I think there are around 3 bolts at the top of the bell housing hidden right at the top

Get the engine crane as close as possible to the cam cover when tying it on.

Remove old engine with the subframe attached, remove subrame from old engine when out & dismantle, attach the engine mounts onto the new engine first, then fix the subrame to them. The subrame only goes one way around.

Attach the gear box to the engine before attaching the subrame to the chassis.

The pipe on the back of the vacuum pump is a right pain in the arse to get to, make sure this is one of the first things that is connected.

I used a jack under the sump aswell as the crane to get the engine lined up to the gear box, i didn't need to loosen up the gear box mount.

The speedo/crank sensor plugs can be confused, if they are in the wrong sockets the engine will start but wont run. if that makes sense!

Hope this helps

It is a pretty easy job, with my limited knowledge i managed to do an engine/ecu swap & clutch & flywheel replacement in 19 hours.[/quote]


thanks helpfull hints.

well i started this at half 11 this morning and after half an hour i was here
20170528_123433.jpg

its now 3 o clock and im here
20170528_144752.jpg


a few questions-wheres the best place to disconnect the power steering lines, the steering rack looks like the place , does the sensor(whatever it is ) on the upper part of the bell housing have to come out and the wire running to that sensor comes round the other side of the bell housing-how do i remove it, its jammed on top of the box?

and fortunately i only had 5 bolts on my bell housing, hmm the garage that did my clutch last, very bold
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06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Re: engine removal guide

Postby scas » Sun May 28, 2017 3:11 pm

all i need now is an engine hoist thing :roll:
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Posts: 775
Joined: Sat Sep 30, 2006 4:16 pm
Location: wexford ireland

Re: engine removal guide

Postby scas » Sun May 28, 2017 4:21 pm

removed the sensor from bell and the wire to it was stuck on one off those plastic things going into a hole
06 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 115 remapped by martyn
04 mk6 2.4 di 90
05 mk6 2.4 di 115
new 06 mk6 2.4 di 115
new 00 mk6 2.4 di 125
can you see a pattern
User avatar
scas
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Posts: 775
Joined: Sat Sep 30, 2006 4:16 pm
Location: wexford ireland

Re: engine removal guide

Postby v8dave » Sun May 28, 2017 4:43 pm

scas wrote:wheres the best place to disconnect the power steering lines

Disconnect the pump from the accessory ladder, then cable tie it and the reservoir to the inner wing.
mk7 08reg 2.4 T350 LWB MHR RWD
mk6 X reg 2.4 T350 LWB MHR RWD - scrapped
mk4 J reg 2.5 L300 LWB MHR RWD - sold on

Notice a trend there ? not too big and not too small
User avatar
v8dave
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