Fitting a 2.2 engine into a Mk6 FWD

[dieselhead123]

We have recently obtained a Mondeo 2.2 Tdci engine block, QJBB engine code.
Over the next few weeks this will be getting built up ready to fit into our LWB crew cab truck, one of our RWD to FWD conversions.

These engines, used in Mondeos produced between 2004 and 2007 start life using the same engine block as the 2.0 Transit, in fact there is even a '2.0' cast into the block, the capacity increase to 2.2lts being provided by using a different crank/rod combination. The idea is to fit the engine out with Tddi transit parts and a 2.0 Tddi cylinder head to provide a 2.2 Tddi FWD engine.

I will make sure to get some pictures up for you chaps, if it all works out well then the 10% capacity increase is likely to be a good power upgrade for a Mk6 FWD.

We have not settled on the management system as of yet, but one option is to use the VP44 from a 125ps 2.4.

Pictures and 'build data' to follow.

TIM

[paul2012]

You're going to beat me too it

I was planning on fitting a 2.2 engine from a Mondeo mk3 ST TDCI next year.

Same engine (QJBB) but sticking with Delphi pump & injectors etc. Plus it would bolt straight into a mk6 FWD
Proved that with Mondeo mk3 2.0 TDCI 130ps engine I have fitted to my Transit. - Also in the process of doing the same on a mk7 for a member on here

[dieselhead123]

Hi Paul, been watching your threads with interest

I don't think we will be retro fitting the Tdci system on this one, (all credit to you for doing that), as the engine is going in an old, (2000), crew cab which was originally a 75ps 2.4 RWD model.

The older RWDs all seem to have the captive nuts, and the internal reinforcing plate in the chassis rails to accept the FWD mountings and the under bonnet loom has integral facility for fitting an electric cooling fan, only single speed though.

The 2.2 Mondeo engine appears to be just a 2.0 block fitted with a 2.4 crank, I wonder if a 2.0 could be overbored to accept 2.4 pistons

TIM

[dieselhead123]

A bit more on this people.

The block is cleaned and painted



The 2.2 Mondeo sump and oil pick up pipe are the same as the Transit parts, so no need to remove these, we did just to have a 'look'
Our Mondeo engine came with no PAS/Water pump, so I am unsure if these are the same as the Transit parts, either confirm this or use your Transit parts as we have done.
The dip stick and dip stick tube are different, so the Transit parts need to be fitted.
The Mondeo oil cooler and filter housing was also missing from our Mondeo block, again we will be using the Transit parts.

Do check when purchasing your 2.2 engine that it bears the correct engine code for a 2.2, this is stamped onto the flat part of the casting adjacent to where the fuel pump mounts. Alternatively, put a piston at BDC and measure the stroke. This should be 94.6mm as opposed to 86mm of the 2.0.

TIM

[Brains_transit]

The block looks great I'll leave my bonnet shut now

[karl]

Hi Paul, been watching your threads with interest

I don't think we will be retro fitting the Tdci system on this one, (all credit to you for doing that), as the engine is going in an old, (2000), crew cab which was originally a 75ps 2.4 RWD model.

The older RWDs all seem to have the captive nuts, and the internal reinforcing plate in the chassis rails to accept the FWD mountings and the under bonnet loom has integral facility for fitting an electric cooling fan, only single speed though.

The 2.2 Mondeo engine appears to be just a 2.0 block fitted with a 2.4 crank, I wonder if a 2.0 could be overbored to accept 2.4 pistons

TIM

a 2.2 litre mrk 7 engine has 2.4 stamped on the crank i have 2 2.2 and a 2.4

i also have a dead 2.0 mrk 6 engine but until i pull it out i can not confirm until i pull it apart

[Finn_Timo]

How about making MTDi version of this and getting all the power available from 2.2 reliably?

Or do you make them anymore, I tried to read topic from MK6 MTDi and forum says like this:

You are not authorised to read this forum.

And I was already signed in...

[Finn_Timo]

Any progress with this engine?

So 2.2 is using crank from 2.4, but what pistons and rods does it have?!

If I am lucky enough, I might get an 2.2 engine with MK7 scrap body which I have already reserved for me... I am going to make another MK6 / MK7 conversion, maybe during this winter. We will see.

[mark barber]

hello guys so would the mondeo 2.2 unit fit straight in to my mk7 transit 2008 model ? or will i struggle what issues might i get thanks guys

[paul2012]

hello guys so would the mondeo 2.2 unit fit straight in to my mk7 transit 2008 model ? or will i struggle what issues might i get thanks guys

Engine will fit.

Although not compatible with mk7's elec systems.

I've just done a Mondeo mk3 engine conversion on a mk7 here viewtopic.php?f=27&t=169904

[dieselhead123]

As Paul2012 says, the 2.2 Mondeo engine will bolt directly to the Transit gearbox, (I doubt we would have started this thread if it were not the case ).
Make sure that you retain the Transit Flywheel and Crankshaft Position Sensor to match your vehicles's management system, Tdci and Tddi are NOT interchangeable as regards the management system.

You need to use the front engine mounting from your Transit, the Mk6 parts will bolt directly to the Mondeo engine. The later Mk6 type, (ally chassis part), will bolt to the Mk7 Transit chassis rail.

I am in the process of renovating a Cylinderhead for our engine, once completed engine assembly will resume.

TIM

[dieselhead123]

How about making MTDi version of this and getting all the power available from 2.2 reliably?

Or do you make them anymore, I tried to read topic from MK6 MTDi and forum says like this:

You are not authorised to read this forum.

And I was already signed in...

Hello Timo, I am sure that an Mtdi will be on the cards for this conversion.

Since so many parts will be 'non standard', engine capacity, injectors, turbo, intake cooling etc, it is unlikely we will find a professional 'mapper' willing to assist us, it would have been interesting to compare results.

The 2.2 PSA engine used in the later Mondeos produces 200ps, (off the shelf with a manufacturer's warranty), so unless the Duatorq engine is just a load of 'pants', ours should do the same

TIM

[Finn_Timo]

Hi Tim

Good to hear that things are going on! Are you putting more info from the parts you are using for this conversion, I was just thinking that what rods, pistons, cams and injectors will be used?

What is the situation with that MK6 Mtdi topic? Has it been erased or what has happened, because it can't be read anymore...

Timo

[dieselhead123]

Hello Timo, thanks again for your interest in this project.

The engine block is a standard 2.2 Mondeo Tdci 155 unit, we know that the bore is the same as the 2.0 and that the stroke is that of the 2.4, I have not removed the internals to check if the rods are the same as the 2.0 or 2.4 Mk6 engines.

We will be using a 2.0 Tddi Transit cylinder head, this allows us to use either Transit 2.4 Tddi 125 injectors, (Delphi), or Mondeo 2.0 Tddi units, (Bosch DHK). The Bosch units are our preference, we have identified larger nozzles for these and have a set of DHK bodies removed from a Mondeo Tddi engine we fitted into a Transit.

I have not looked at the camshafts in detail at this point, there are so many variations of these engines so there might be different cam 'profiles' available. Our engine will require us to use a FWD inlet cam to provide the 'drive' for the Water pump/PAS pump, but all the camshafts will physically fit in the cylinderhead.

The valves are larger on the 2.4 versions of these engines, but due the the valve 'footprint' the 2.4 valves can not be used with the smaller 2.0/2.2 bore, it might be possible to use the 2.4 exhaust valves though. The ideal 'solution' would be to overbore the block to accept 2.4 pistons

I will continue to update this thread as progress is made.

TIM

[twofords]

And whats happening with the mk6 mtdi post as above?