How to replace 306 1.9 TD DTurbo XUD9 DHY engine?

[shazilla]

Hello All!

I have a 306 1.9 TD DTurbo with a XUS9 DHY engine.

I need to replace the engine in the car.

I manage to get another low mileage, running car with the same engine.

The car was a MOT failure due to rust, but the engine is solid.

Can someone please give me a step by step guide on how to remove and re-fit?

Does anyone have any tips?

I would be really greatful!

Thank You

Happy New Year

[Jimbo]

Bit of a mission to write it out but.
Remove fuel lines, wiring, clutch cable, some coolant pipes.
drain gear oil, remove driveahafts, the lower mount
Wack engine crane in and remove top engine and gearbox mount

Good luck if u think anyones gonna write.anymore than that

[Danny2009]

Where you from was going to write it out but there's too much it's pretty straight forward

Leave the loom on the engine and undo it from the chassis leg passengers side

[Tom]

Take the front end off! Up off drivers side mount, kick it out the bottom of the gearbox mount and swing her out.

[Daniel306]

Buy a haynes manual?

[shazilla]

Hello Everyone!

Firstly Thank You Everyone for replying!

Update on the work I have done so far:
1. Removed the Battery.
2. Removed the Wiper Blades and Arms.
3. Removed the Front Bumper with the Fog Lights.
4. Removed the Slam Panel with Headlights, Grill and Bonnet Latch.
5. Removed the Cooling Fans, A/C Condenser, Radiator and Expansion Tank.
6. Removed the Screen Wash Reservoir (Tank).
7. Removed the Power Steering Reservoir (Tank).
8. Removed the Battery Box.
9. Removed the Inter cooler piping that goes to Air Filter Housing.

I’m kinda stuck on what I should do next.

Is it easier to remove the engine and gearbox with the hoist?

Or would it be easier to drop the whole thing with the sub frame and suspension struts?

Hope this information helps. I would be really appreciate any help!

Thank You

Happy New Year

Sam

[Craigus]

Why did you take the wipers off?

Be easier to do with the hoist

[Tom]

Yeah take the engine and box in one. Gotta do the clutch cable and the driveshafts out yet. Unplug the engine loom from the nearside chassis leg. Have to unplug the heater matrix hoses aswell. Im sure theres more i have forgot. If its connected to the engine and chassis it needs to be unplugged from the engine.

[Piggy]

You basically didnt need to do any of that!!

Remove shafts, battery, loom at chassis leg, remove cables and pipework and exhaust.
Undo bottom support.

Get hoist onto the engine

Undo two final mounts and remove engine

[Danny2009]

Looks like your struggling a little as my post above where are you lots of helpful members on here

[Jiffy]

I've taken 2 of these engines out. Two things I struggled with:
1) Watch the water hose connection thing at the back of the engine. I broke it really easily on the first engine so was super careful on the second and still broke it. The part number is 1336G4 if, like me, you end up having to buy a new one.
2) The gearstick linkages are fiddly and the rubber can come apart so be careful with them.

I really recommend getting a thing to adjust the angle of the engine as you really need to tilt the engine a lot to get it out as the gearbox goes under the body.

[Stephen]

I removed one once, just hit everything with a big f*ck off bar till it fell out

[Mitch]

I removed one once, just hit everything with a big f*ck off bar till it fell out

That actually did happen, believe it or not

[Piggy]

Wrap chain around engine.
wrap other end of chain around big tree.
Start engine.
Select reverse.
Accelerate at full speed in reverse.
*wear seat belt
*have someone video it

[shazilla]

Hello Everyone!

Firstly thanks once again everyone for replying!

Craigus, I took the wipers off because I was stuck on what to do next!

Tom, I have disconnected the clutch cable, drained the transmission fluid. I have also unplug the engine loom from the nearside chassis leg. I wasn’t able to unplug the heater matrix hoses as it wouldn’t budge, so sprayed with WD40 and left overnight! Thanks for your help!

Piggy, This is my first XUD engine removal, the car will be scrapped once I have got the engine out from this donor car! I’m trying to take out as many things I can from this car, so I can keep as spares for the on that this engine will be going into! Thanks for your help!

Danny2009, People are still away for Xmas and New Year’s!

Jiffy, I wasn’t able to unplug the heater matrix hoses as it wouldn’t budge, so sprayed with WD40 and left overnight! Is it worth heating slightly with a heat gun to soften plastic and rubber seals? How would you recommended removing the gearbox linkages? Spraying with WD40 or heating slightly with a heat gun? Thanks for telling me about tilting the engine, hopefully will make my life a lot easier! I really appreciate the pictures that you have added.

Stephen, How many times did you hit it?

Mitch, Have you tried that?

Piggy, I don’t have that many chains! LOL

Update on the work I have done after last update:
1. Removed the Front Plastic Wheel Arches Gard’s (Covers).
2. Removed the Air Filter Housing.
3. Removed the Battery Box Mounting plate (above Gearbox Mounting).
4. Removed the A/C Pipes.
5. Removed the Engine Mounting plate (above Engine Mounting).
5. Disconnected the engine loom on the nearside chassis leg.
6. Disconnect wiring from chassis legs and centre support.
7. Disconnected the Clutch Cable.
8. Disconnected the Accelerator Cable.
9. Drained Transmission Fluid / Gearbox Oil.
10. Drained Engine Oil.
11. Removed Badge from Bonnet (before someone knicks it).

Job list for Tomorrow:
1. Remove Both Driveshaft’s.
2. Disconnect Gearbox Linkages.
3. Remove Catalytic Convertor / Exhaust.
4. Remove Heater Matrix Pipe.
5. Might Chop Off the Front-end, might make it easier to pull / slide the engine out, rather than lifting it out.

Anyone have any tips or pointers?

Once the engine is out remove everything else!

Thank You Everyone for all your help.

Sam

[Dave]

No one run any exhausts these days?

[Tom]

Metal clip on the heater matrix hoses then there's like a plastic tab and they'll pull off. Might worth using some kind of bar to gently help them out as they can be though sometimes!

[shazilla]

Today I only managed to disconnect the gearbox linkages, ended up breaking long nose pliers!
Also I have remove small Drive shaft and Passenger Side Wishbone.
Still no luck with that heater matrix pipe.
I managed to remove it on the other end from head/block luckily has a jubilee clip!
Didn't try the one that goes to the water pump as it had a hose clip!

[Tom]

Love the methodical approach to this. Most would just cable tie this up here and cut that then yank it out! <including me before anyone gets high and mighty.

[shazilla]

Today I managed to:
Remove the Long Drive shaft and Drives Side Wishbone which was a lot harder to take out the passenger side one, as this ball joint was harder to get out for some reason.
Finally got round to getting the heater matrix pipe, ended up wedging it with and 19mm spanner.
Today, I also managed to remove it on the other end from the water pump, this side had a hose clip which was a pain in the arse to get out, ended you cutting my hand!
But i removed the whole pipe in one peice.
Tomorow i need to remove the CAT! Then engine is ready to come out.
How do i remove engine / gearbox mountings?
Sam

[Tom]

Bottom mount is a 16mm bolt and nut just pull that out engine might rock back a touch but nothing to worry about.

Then get your crane and support the engine somehow. Now theres 1 16mm nut on the top engine mount by the cambelt and another on the gearbox mount. Then you lift the engine off the top mount and swing it out a bit then use a bar or your foot to push it down through the gearbox mount and then your out. Easy peasy.

[shazilla]

Thanks For you help TOM and Everyone Else!
Got the engine and gearbox out! ended up breaking the intercooler pipe but everything else good!.

[shazilla]

Car is now being striped down.
soon Scraped.

[shazilla]

Car has been striped, shell is going on Thursday!
Then Removing engine from other car and puting this engine in!
Thanks For all your help!

[shazilla]

Starting to remove other engine tomorow.

[shazilla]

other engine now out, got to get this one in!

[shazilla]

Now finally getting a chance too put new engine in!

[Danny Wideboy]

Yawn.

Reported.

[Danny Wideboy]

Car has been striped, shell is going on Thursday!
Then Removing engine from other car and puting this engine in!
Thanks For all your help!

Makes absolutely no sense.!

If the shell is going, then what are you putting the "new " engine into?!
Fail.!

[Seb_Ryan]

Car has been striped, shell is going on Thursday!
Then Removing engine from other car and puting this engine in!
Thanks For all your help!

Makes absolutely no sense.!

If the shell is going, then what are you putting the "new " engine into?!
Fail.!

He is removing an engine from another 306, then putting this engine he has taken out into that shell? No?