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Thread: 2l DOHC engine removal.

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  1. #1 2l DOHC engine removal. 
    frequent forum contributor Club Member stewartdjones's Avatar
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    The engine has over the last 2 years sprung some bottom end oil leaks and it was pointed out at the last MOT. They seem to be coming from the sump gasket and the front crankshaft seal.
    So I am starting to plan the removal of the engine and gearbox over winter, this will entail removing the front end of the body, lights and radiator, this is not a problem to me, but has anybody removed the engine without removing the front wings?
    Would be grateful of any advice as to this work to be done.
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  2. #2 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Hi Stewart. I've done 2l DOHC engine in/out several times. If you are going to only work on the engine I would leave the gearbox in place.
    1. Remove bonnet. You can get better access if you remove the engine bay side panels but it isn't necessary.
    2. Remove radiator.
    3. Disconnect battery, wiring to engine, fuel lines and hoses from engine.
    4. Undo exhaust manifold and move to one side.
    If you don't need to remove the gearbox (i never did) then
    5. Fit engine hoist to the two eyes at the back and front of the engine. Take some of the weight of the engine.
    6. Remove starter motor
    7. Undo the ring of bolts between gearbox and engine
    8. put sling under the gearbox to take its weight.
    9. Undo the nuts holding the engine mounts to the chassis and lift the engine slightlly to take its weight. Tighten sling.
    10. remove the bolts holding the engine mounts to the engine.
    11. Swing the engine forward to disengage it from gearbox input shaft.
    12. There should be enough room to lift the engine straight up.
    Installation is the reverse!
    Simples.
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  3. #3 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member stewartdjones's Avatar
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    Thanks Chris for your experience, I am now thinking “do I need to take the box out?” Maybe not, I will now think about that.
    Did you leave the nose cone in place?
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  4. #4 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Yes. nose stayed in place.
    I don't know if you can take out engine and gearbox in one peice with removing any more. When I installed it as a unit there were no panels fitted, and the gearbox has remained in place ever since.
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  5. #5 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member stewartdjones's Avatar
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    Thanks for that, if I leave the box in, it means that I do not have to remove the electrics on the front, it will save time.
    Did you use a mobile crane hoist?
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  6. #6 Re: 2l DOHC engine removal. 
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    You can remove the engine and gearbox on a V8 but you have to remove it as one lump.
    I has been dropped out below ( by John M)
    but I always lift it out with a crane.
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  7. #7 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Yes you can leave all the electrics to the lights etc. in place.
    An engine crane would be useful. I dangle the engine from a beam in the garage and push the car back after I have freed the engine and lifted it to clear the nose cone. With the car pushed back I lower the engine onto a home made trolley with casters so I can push it around the garage. I don't have a lot of room as I have a standard single garage so its a bit of a squeeze.
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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  8. #8 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member stewartdjones's Avatar
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    I haven’t got much headroom in my garage so may have to remove lights and nose cone, will remove some of the engine components to allow easier access due to leaving wings on.
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  9. #9 Re: 2l DOHC engine removal. 
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    My local garage changed the crankshaft seal on my 2.1 DOHC injection engine without removing anything at all. They had a puller which fitted between the pulley and radiator. Looking under mine I reckon the sump gasket can be changed in situ. Just raise the car high enough to work comfortably. David.
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  10. #10 Re: 2l DOHC engine removal. 
    frequent forum contributor Club Member chris_cussen's Avatar
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    Distance between floor and the bottom of the beam I use is 2.25metres.
    I put a chain around the beam and use one of these hoists .
    Cabrio, Omex 2.0l 150bhp Zetec blacktop, Omex ECU and wiring loom.
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