Volvo 1.6 D2 engine swap

[E-bmw]

Good day gents, I have an issue with my d2 & need some technical assistance.

The darned thing has a suspected cracked block & I am now leaning towards a full engine swap.

I can get one with lower mileage and already have a full clutch kit as I expected to need one soon.

I (assuming I go ahead) will be fitting a new cambelt kit etc also.

The bits that I need advice with are as follows.

Is it a real mare to do, or just a take your time, do it yourself job for a well equipped & experienced amateur?

Are there any major pit falls?

I was going to put my injectors in the new engine along with turbo & EGR, is there anything else I would need to swap to prevent any electronic gremlins when re-commissioning?

[stevemcs]

I think we have done a 1.6 ... it mostly Ford hardware on there.

Get all the gaskets for inlet, exhaust, turbo etc. Yes do the cambelt while its out, and you are correct, use your injectors, in fact use all the sensors from your engine. That way you knew it was running before you took it out and when it goes back in it eliminates something on the used engine as being a dud.

Take your time, make sure you have the space, take pictures of everything and lay everything out neatly.

[E-bmw]

Thanks Steve, much appreciated, other sensors is not a bad shout, will see how I get on.

Is it easier to go engine up or engine down do you think?

I will likely leave the 'box on the engine to make the clutch easier.

Edited by E-bmw on Saturday 14th October 21:32

[stevemcs]

Slightly different in a workshop, you can either lift some, drop some on a pallet and lift the car up or just pull it out the front. I guess it depends on what you have the space for but would think up and out.

We would normally take the engine and gearbox out as one.

[E-bmw]

Once again, I thank you.

[stevemcs]

Give us shout if you want any part numbers, oh and the replacement engine - make sure you get the registration number then if you need to check part numbers against that car you can.

[E-bmw]

Many thanks, but I think I have them all, or all the obvious ones anyway.

Good call on the reg number, didn't think of that one.

[Krikkit]

Engine swaps are easy if you're prepared to sink the time - take lots of pictures as you go, make sure you have a crane (it's much much easier), and imho the most important tip I could give you is that if you can remove something to make it easier, just do it!

Fetch the old engine out and sit it side by side with the new one so you can swap/compare all the ancillaries etc. If you're in the NW I'd be happy to give you a hand if you get stuck.

[Bonefish Blues]

https://www.volvov40club.com/threads/d4162t-cracke...

May assist

[E-bmw]

Krikkit said:

Engine swaps are easy if you're prepared to sink the time - take lots of pictures as you go, make sure you have a crane (it's much much easier), and imho the most important tip I could give you is that if you can remove something to make it easier, just do it!

Fetch the old engine out and sit it side by side with the new one so you can swap/compare all the ancillaries etc. If you're in the NW I'd be happy to give you a hand if you get stuck.

Good advice, I intend to se a crane & MANY thanks for the offer, alas I am near York but thanks again.

[E-bmw]

Bonefish Blues said:

https://www.volvov40club.com/threads/d4162t-cracke...

May assist

Thanks for that, will have a look.

[E-bmw]

For those following this it now looks like it may not be required, I will now be starting another thread "V40 Low coolant level warning" so hopefully, I don't need any further replies to this thread.

Many thanks for the input to date it has been very informative & will be useful if I am proven wrong in the previous statement.

No more replies to this for the moment please.