Fitting a 2.2 engine into a Mk6 FWD

[lancy]

Hi I'm interested to hear how well this set up works? Power and economy, is there any gains or differences?

Nice work!!

[dieselhead123]

Hi Lancy. We have tried lots of different 'set-ups' with this van, just to see what could be achieved and what we could get to work. From day one the 2.2 showed that more torque was available, with the longer stroke of this engine we sort of expected this.

Initially we ran a 115ps 2.4 Vp44 pump, 115 Transit 2.4 injectors and a 115 2.4 Transit PCM to 'match' the later 'digi' Transit cluster we had fitted. This all worked fine, was reliable, with no noticeable increase in consumption when driven as if it were a standard Transit, but has lots more 'get up and go' when asked for. We tried a VNT turbo on the engine, (with the vanes held fully open), full throttle acceleration was excellent. But, this won't work using a Transit Tddi PCM as the PCM does not have the facility to control the VNT, although it did show that having a VNT fitted and correctly working would give a lot more performance.

We now needed a Tddi PCM that had VNT control capability, the early Tddi Mondeo fitted the bill perfectly as it not only had a VNT turbo but also had cruise control, frost warning lights and other features only found on Mk7 Transits.

But we wanted to see if we could 'enable' some of these additional 'features' by using the Mondeo 115 Tddi PCM.
One of the main 'let downs' of the Mk6 is that Ford didn't offer cruise control, by using the Mondeo 115 Tddi PCM we could keep the Tddi management system and use the Mondeo cruise control.
I can't say if the Transit digi cluster will work with the Mondeo PCM as we didn't try this parts combination, preferring to use the better looking Mondeo cluster as it has a 'cruise on' warning lamp.

So, fit the Mondeo Tddi PCM, early models have VNTs, fit the Mondeo cruise steering wheel and add all the additional sensors and wiring to the Transit wiring looms.


I'll get some pictures posted up of the additional sensors we fitted.

TIM

[dieselhead123]

Right then people, found some pictures of the additional sensors we had to fit, all these are used with the early Mk3 Mondeo 115 Tddi PCM that we are running in the van.

Barometric pressure sensor, this has three wires that connect directly to the PCM plug, it is located about half way up the driver's side A pillar on the Mondeo and can be found once the Mondeo cluster is removed. We obtained the sensor, the wiring plug and a short length of wiring harness from the Mondeo. For our convenience we mounted the sensor at the rear of the PCM beneath the dash top cubbey hole on the Transit and run three wires to the Transit PCM plug. here is a couple of pictures of the BARO in place, the sensor is identified in RED



We ran the three wires from this through the round grommet in the bulkhead close to the PCM and attached these to the appropriate pins on the PCM plug


The Transit PCM plug needed the pins adding to the correct locations, the PCM plug needs to be dismantled to accomplish this.

TIM

[dieselhead123]

The next part to be fitted was the MAF sensor, the Tddi Mondeo uses a MAF sensor on the airbox, the Tddi Transit does not.

We used an airbox from a Tdci Mk6 as this has provision for a MAF sensor, fitting the Mondeo MAF sensor we knew to be good. It turn out that the Transit Tdci MAF sensor is the same as the Tdci Transit one!

Here we see the Mondeo MAF sensor fitted in the Transit airbox, the Mondeo MAF sensor plug was used with a short length of wiring loom. This provided the correct colour wires to match up with the Mondeo wiring diagram.


The four wires on the MAF sensor, (two of the pins are unused), were extended and connected to the correct pins on the PCM plug. A bit of tape around the wires will do for now until we confirm all is well.


TIM

[winterheating]

Good job, hows it gone over the year?

[dieselhead123]

Good job, hows it gone over the year?

Done a few different installs on these now, some just using the customer's VP30 and PCM as fitted to their van. But our one with the Mondeo Tddi PCM works well, nice to have the additional features such as cruise and the external air temp dispiay on the dash. The external air temp was a bit strange though, with the sender disconnected, (before we bothered to fit it), the engine was in some sort of limp mode and dispayed an error code! We did not expect the external air temp to be used in PCM 'calculations', but once we fitted one the problem went away.

This is the early petrol Mondeo cluster, no external air temp display because there was no sensor fitted;


We now have a Mondeo diesel cluster fitted, the rev counter was accurate, just looked a bit silly with 8000 rpm showing!

Learnt a lot by doing these, should help get some of the additional features working with the petrol engined ones.



TIM