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Thread: Not so much a rebuild as an engine swap

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  1. #1 Not so much a rebuild as an engine swap 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Last year I managed to destroy my Ford 2.0 DOHC engine last year by having the head gasket go, followed by completely getting the engine timing wrong resulting in valve hitting pistons, damage to the camshafts. Doh!

    Anyway I got a replacement engine from Lee, however the original ran on Carbs and the replacement has fuel injection. It came with wiring loom, which even included the ABS system. However the ignition module seemed to be missing and to be honest I was daunted by the number of wires in the loom. I did consider just chopping out the ones that were not connected to the engine wiring loom but I wasn't sure what the side effect of that might be.

    Seeing an nice blue Marlin around Weymouth as I was going to and from work made me decide to final get off my backside and get on with the job. Still worried about the ECU I have finally decided to get a Megajolt ECU.

    So yesterday it was take out the old engine and get the replacement ready for insertion. I tweaked by back yesterday so today is a day of rest, however a few questions have arisen and I am hoping that the knowledgeable of you out there may be able to enlighten me.

    Picture 1: curly black pipe with rusty object in it. Its obviously the fuel supply. What is the rusty object? should there be a jubilee clip on the pipe?
    Picture 2: Pressure regulator. Where does the black pipe go?
    Picture 3:Plenum chamber: engine side. What goes on here? Where does it go to?
    Picture 4:Plenum chamber: outside side. What goes on here? Where does it go to?
    Nearly final question, Vacuum takeoff for the servo. Where does that go (if none of the above).
    Final question: Low pressure fuel pump at the rear of the car, I plan to put a high pressure pump in the engine bay. Is a swirl pot necessary?
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    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  2. #2 Re: Not so much a rebuild as an engine swap 
    Club Member lil_red_roadster's Avatar
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    I have some sympathy Chris - having suffered various mishaps lately I'm struggling to find the enthusiasm to strip the engine yet again (this time to find out whether the rings have gone or just a stuck hydraulic lifter). Tempted to throw a sheet over the car & pretend it doesn't exist..!

    I don't know the Ford engine but conceptually...

    - The fuel pressure regulator goes at the end of the fuel rail...surplus fuel needs a return circuit to either your swirl pot or back to the tank.
    - The fuel pressure regulator needs a connection to the plenum to provide the necessary vacuum (this will be a small diameter hose).
    - You will need a swirl pot unless you have a sumped fuel tank (to prevent fuel starvation on cornering).
    - The swirl pot (if fitted) will need to have a return line to the tank.
    - Servo hose will fit to the plenum (probably to the largest available spigot)
    - Only use good quality injection-rated hose & always use barbed fittings & clips for the pressurised side (fuel at 3 bar goes a very long way)
    - Have a fire extinguisher handy at all times when messing with injection systems..!
    Marlin Roadster, LWB...1860 B Series + Ford Type 9
    Renault Espace 54mm front calipers, vented discs, cycle wings and adjustable tie-bars.
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  3. #3 Re: Not so much a rebuild as an engine swap 
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    HI Chris
    Pic 1, yes and yes.
    Pic 2. the pipe goes to a tube on the underside of the air intake plenum at the front just under the throttle butterfly.
    Pic 3. This should go to the amplifier unit. I will try to photograph it.
    Pic 4 is the point for the idle control valve to attach to.

    efi1.jpg

    EFi2.jpg This is the amplifier . It is mounted remote from the engine. My engine didn't have one when I bought it but i found one quite easily on fleabay. Make sure you keep the wires in the loom for it.

    EFi3.jpg
    This is how I attached the idle control valve. Again easy to come by if you dont have one. Plenum to intake side then a filter on the end which would have attached to the air box.
    Last edited by cameronfurnival; 01-06-2014 at 05:19 PM.
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  4. #4 Re: Not so much a rebuild as an engine swap 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Hi Cameron,
    Thanks for the reply!
    A couple more questions I am afraid.
    I've attached another photo.
    I can't see where the other end of the idle speed valve lives, am I stupid or what?

    I have a dangling servo vacuum pipe. I assume it goes onto one of the connectors on the left of the manifold.

    Chris
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    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  5. #5 Re: Not so much a rebuild as an engine swap 
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    Here is a pic of the original Sierra installation Chris. If you look to the left of the plenum you will see a rubber hose coming off the spigot. It runs round the front to the idle control valve which mates to the plastic air trunking. You can see it in these pics.
    2_0_DOHC_EFI.jpg
    dohcefi.jpg

    The spare bit of pipe looks like it might be the vacuum take off for the servo so goes to the takeoff on the right (capped on yours), although it doesn't matter which one you use.

    And heres a pic I got from a foreign site which shows where all the sensors are...

    dohcsensor.jpg

    MAP - Manifold Absolute Pressure
    FPR - Fuel Pressure Regulator
    TPS - Throttle Position Sensor
    IATC - Intake Air Temperature Charge
    IACV - Idle Air Control Valve
    CPS - Crankshaft Position Sensor
    CTS - Engine Coolant Temperature Sensor
    Note the way the Idle control valve has been plumbed in as the original air cleaner is no longer being used.
    Last edited by cameronfurnival; 02-06-2014 at 07:02 PM.
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  6. #6 Re: Not so much a rebuild as an engine swap 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Brill!
    Thanks a lot!
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  7. #7 Re: Not so much a rebuild as an engine swap 
    frequent forum contributor Club Member chris_cussen's Avatar
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    ECU and HP fuel pump ordered, plus fuseboxes and relays, also idle control valve and new TPS as I managed to break the original when installing the engine

    Cameron, where did you get your air filters from?

    Chris
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  8. #8 Re: Not so much a rebuild as an engine swap 
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    the air filter is in fact a K&N filter for a VW beetle iirc It fit straight on the end of the throttle body and needed just a jubilee clip tightening.
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  9. #9 Re: Not so much a rebuild as an engine swap 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Next question in an infinite series. Idle control valve - did you have to make the black widget that has the air filter on one side and the pipe to the plenum chamber on the other side. Is the IDC floating in space or rixed to a bracket?
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  10. #10 Re: Not so much a rebuild as an engine swap 
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    yep i made a plate out of steel and welded on a couple of tubes. It is attached to the plenum via a 2" piece of pipe so is quite secure and doesnt wobble.
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