2.0 hdi engine swap

[jayspug86]

hi guys not sure if this the right section but im looking for someone local to e who fancys fitting a new engine for me for some ££££

[Toms306]

Might help if you put a location in lol.

I would, but no-ones local to me so I doubt you will be.

[jayspug86]

sorry cambridgshire

[Toms306]

Miles away then! But I'm sure someone can help.

If not, its not hard to do on your own with a crane.

[jayspug86]

how much is involved and is it all straight forward

[Toms306]

Very easy tbh, if I can manage it it cant be hard.

Simply:

Remove bumper/grill/rad/fans
Remove battery and airbox
Remove wheels and driveshafts
Remove cat pipe
Unplug loom from chassis leg
set up crane
remove mounts

Then the same to refit. Obviously if you want to change cambelt or clutch, do it with engine out!


If you look for my moonstone project thread there are a few pics of the swap in there.

[bashbarnard]

We can always guide. There not too bad. I think toms306 has done a few more than me. I pull xuds out though. Almost same.

[jayspug86]

how hard is the exhaust to remove from turbo

[bashbarnard]

Two bolts. Not too bad from memory. Bit of a fiddle on your back

[Toms306]

Just need a 10mm deep socket with about 4 extensions lol. And expect the turbo stud to snap and the spring to hit your forehead.

That's really not one of the hard parts though!

[jayspug86]

right my new engine has just arrived and its from a 206 hdi 90 but a few things look slightly different to mine I was under the impression the engines were the same?

[Toms306]

The block should be the same, the loom and ancilliaries may be different.

Which bits look different?

[jayspug86]

the turbo is like a v clamp rather than the 2 bolts and power steering pump has a resvoir on top as where mine is near water bottle

[Toms306]

Ah yeah, the turbo exit is definitely different as the cat pipe is. And yep, the PAS pump is different as well.

You should be able to fit your ones to that engine though.

[jayspug86]

can I unbolt the exit on my turbo and swap it with the turbo fitted to new engine

[Toms306]

Tbh I can't remember, I only know as I had a 206 with a broken cat...wanted to swap the cats with a spare 306 one but couldn't lol.

It should be easy to see if the turbo elbows look the same though, though they rust in solid usually. I'd just swap the whole turbo over myself unless yours was knackered.

[jayspug86]

yeah turbo sill has gone and the one iv got is fairly low milage ( so im told lol )

[Toms306]

Hmm, ok, well in that case check if the elbow is the same then. I'm pretty sure its the same K03 turbo.

[jayspug86]

il have a look tomorrow im thinking of fitting fmic while engines out

[jayspug86]

had a look today injectors and fuel rail are bosch and mine runs siemans ecu I believe

[Toms306]

Is it a 306? I've not heard of 306 HDi using a Siemens ECU.

[jayspug86]

no its a berlingo van sorry should of mentioned that lol

[Toms306]

Oh right, probably should've mentioned that a while back haha.

[jayspug86]

all the engines are the same though I believe

[Toms306]

The blocks are the same, different stuff bolted to them though lol.

Can you swap your injectors etc onto the new engine?

[jayspug86]

yeah cant see why not was hoping to use the new injectors as there lower milage

[Toms306]

Ah well, if they're decent sell them on and get some money back.

[Poodle]

Yeah you should have mentioned that before lol. If you want to swap fuel systems about then you'll need the corresponding ecu, which obviously requires matching bsi and immobiliser gubbins. If you want to use the better condition turbo the easiest way would be to swap the chra off the new turbo into your old housing.

[jayspug86]

update for today the engine runs fine with no smoke at all but if I gently increase the revs it starts to puff blueish smoke just as turbo spins up so decided to sell van as spares and break new engine i bought for parts whats worth selling off a hdi engine??

[Poodle]

That's a bit weak, sorry to hear it. Rods, pump and injectors will all sell as a rule.