Changing the engine

[Mighty]

I now have 2 2.0 hdi berlingo's with blown head gaskets... Both between 200000k and 240000k. Is this normal?

Is a rhy engine from a peugeot 406 identical to the rhy engine in the beelingo. That is, will a swap present any problems? Also, can I use a rhz 109hp engine?

[polar]

200k sounds a little low for the 2.0hdi for head gasket trouble but not unheard of. Might be somthing to the coolant type you are running and frequency of changes.

The block out of a 2.0hdi peugeot should be the same.

[Mighty]

I am more worried about the top and all the connections though. I need it to be "plug and play".

Both cars are blowing exhaust into the coolant and also loosing coolant. One is still driveable with a top up now and then though. I drained the cooland, cleaned the system and used a leak repair fluid a week ago, but I have my doubts. The coolant I drained was like coffee, only more black...

[brodfather11]

Are there some engines with a EGR cooler , don't know if yours has one.
Could it be allowing exhaust gases into the coolant system (similar to the faulty oil coolers that leaks oil into the oil ).

[polar]

Are there some engines with a EGR cooler , don't know if yours has one.
Could it be allowing exhaust gases into the coolant system (similar to the faulty oil coolers that leaks oil into the oil ).

Hi brodfarther11 yes there is a water cooled EGR cooler on the 2.0hdi but i doubt there would be enough pressure in the cooler to pressurise the coolant, i have also never known a EGR cooler on the 2.0hdi to become faulty.

However it is also unusual for head gaskets to play up on this engine - i suspect corrosion due to old coolant being the problem.

[Mighty]

No egr cooler on this one. Head gasket corroded?

How big of a job is swapping the engine on these? Does the AC system complicate anything?

[polar]

If you swap the engine you will get an immobiliser problem so you will have to change over the pump and injectors from the old engine. AC cant see any big problems, but to be far it would be far easier to replace the head gasket.

On a side note all the 2.0hdi's i have seen have a EGR cooler. Yours may be different?

[Mighty]

Okay. I heard the injectors are a pita to remove on these HDI engines, and will often break. Do I really have to replace the injectors when both engines have the same siemens system?

Can't new injetors be programmed in?

The pug 406 109hp did have a egr cooler, but this one does not. Just a straight exhaust pipe into the egr.

I have seen it mentioned in here a couple times that removing the top on these are hell and it's easier just to replace the engine.

[Gadgetman]

I don't know the 2.0 engine, but...
On most engines, replacing the gasket is an 'in car' procedure. In other words, it can be done at home in an evening if you plan ahead and have everything ready.

Replacing an engine is.. yeah... as much work as it sounds like.
Pulling driveshafts from the gearbox(remember to get new seals... ), which means loosening the lower wishbone on both sides. does the 2.0 have the RH side driveshaft passing through the rear engine mount? Yeah, that's a bit of a pain, too.
There's a sensor on the flywheel(on some engines, at least), but it's actually mounted on the bell housing, and there may be different plugs.
Transferring the ECU and possibly injectors to avoind immobilizer mess.

[Mighty]

As far as I understand, the engine has to be removed or at least dropped down in order to get the top off. Or else the firewall gets in the way.

From what i've read from people who have done it, removing the engine is 10 times easier than getting the top off in the car.