Engine swap 2.4 Euro4 dressed as a Euro5 in a Mk8

[Airthies]

As the title suggests.... This is about fitting a Euro4 2.4 Mk7 engine into a Mk8 that originally had a Euro5 2.2 engine and running as a Euro5 rather than a Euro4.

Firstly:
Is it a straight swap? NO!!!!
is it an easy conversion? Not really.
Is it worth it? That is subjective.
Is it worth doing it again? Hmm, doubtful.

I started with a decent 140ps 2.4

Removed all the ancillaries, manifolds fuel system etc down to a bare block and head.

Drilled and tapped block to take the E5 fuel pump which is 3bolt (old E4 is 2bolt)
Did the measurements and made a jig to drill the pilot holes and tap them straight.
Swapped rocker ladder and rocker cover.
Fitted E5 fuel pump, rail, injectors and pipework.

E4 glow plugs, (E5 are smaller and 4.4v E4 are 12v) and common power connector rail.
Made a resistor bank for the E5 glow plug relay to sense so it didn't flag a glow plug fault. (Could also be mapped out).
Going to fit a high load relay to run the E4 glow plugs which will be timed from initial ignition on, for cold starting.

Mostly E4 cooling system apart from the thermostat housing as it has the temp sensor.
Vacuum pump on top of water pump.

E4 exhaust manifold and modified E5 EGR cooler.

E5 steering pump, mounted in the same position as the original E4 pump, bolt patterns the same but high pressure hose needed manipulating and a new support bracket made.

Mk8 alternator needed the rear housing rotated a 1/4 turn so it wouldn't foul the engine mount.

Mk7 belt, tensioner and idlers.

Mk7 E4 140 turbo, using modified Mk8 E5 actuator and custom mount plate.
E4 CAT and Flexi to first joint with DPF injector mounted into the downpipe elbow at the same position as the original.

It's had a boost issue which was solved by making sure the turbo actuator was sweeping the right way and making a new mount bracket to reposition it for optimum stroke and leverage.





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[mompracen_bs]

The day someone creates a kit to do a similar job and get rid of EcoBlue 2.0 from the Transit and Transit Custom FWD, many people will be celebrating.

[Altransit]

The day someone creates a kit to do a similar job and get rid of EcoBlue 2.0 from the Transit and Transit Custom FWD, many people will be celebrating.

Whilst it would indeed be a challenge just to change the engine, you would probably need to have a clone with an original engine, just to take for the MOT every year

[Airthies]

The day someone creates a kit to do a similar job and get rid of EcoBlue 2.0 from the Transit and Transit Custom FWD, many people will be celebrating.

Won't be me doing any FWD I'm afraid.


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[BHM]

My question is why? What advantage over a 2.2 155 do you have? Or is this a project for overseas markets?

Interested BHM

[Airthies]

My question is why? What advantage over a 2.2 155 do you have? Or is this a project for overseas markets?

Interested BHM

Why? Because I can, doesn't mean I should or think it's worth while for everyone.
Advantages? Cost.
I've got two knackered 2.2 engines and spare good 2.4 engines that don't need a full rebore rebuild.


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