Engine removal advice

payydg · Nov 4, 2018

Going to be taking out my engine (200tdi defender) soon. Not done it before any one have an advice or tips?

Off the top of my head the steps are:

Drain oil and coolant and disconnect heater matrix.
Remove fan, cowling and air box
Remove radiator, intercooler and grill
Disconnect electrics - alternator, earths , fuel solanoid, glow plugs.
Disconnect vacuum pump - just undo at engine?
Disconnect power steering pump - do I need to drain this or can I just disconnect pips at the pump?
Disconnect fuel lines and injectors
Undo mounting bolts

Someone said you should then lift up everything put a block of wood between the bell housing and the cross member and then lower everything down onto that and then undo bolts and separate?

How’s best to separate the engine and transmission, carefully use a prybar?

Also, how on earth does the engine fit onto an engine stand?

brian47 · Nov 4, 2018

My advice?
Get somebody else to do the lifting, and you can then just do the grunting.

payydg · Nov 4, 2018

brian47 said:
My advice?
Get somebody else to do the lifting, and you can then just do the grunting.

Sounds like my sex life

Marmaduke · Nov 4, 2018

The engine stand I had connected to the back of the block once I'd removed the flywheel and starter/flywheel housing.

Marmaduke · Nov 4, 2018

Oh and it's way easier to remove the floor and transmission tunnel to allow access to the gearbox bolts

Flossie · Nov 4, 2018

The very first thing you do is disconnect the battery.
Mines a disco 200 in a 110 but I can unbolt the steering pump and leave it connected.
Take the bonnet off or tie it up against the screen.
Oil cooler and pipes will pee oil everywhere so watch out for that.
Have you got the lifting eyes still attached? Sometimes missing, one lh rear of engine and one on the front.

Flossie · Nov 4, 2018

Marmaduke said:
Oh and it's way easier to remove the floor and transmission tunnel to allow access to the gearbox bolts

Mines all held in with stainless nut bolts and screws so it's a doddle, pita with rusty chewed up fastners

payydg · Nov 4, 2018

Marmaduke said:
The engine stand I had connected to the back of the block once I'd removed the flywheel and starter/flywheel housing.

As in just screwed in? are there threaded holes at the back?

payydg · Nov 4, 2018

Flossie said:
The very first thing you do is disconnect the battery.
Mines a disco 200 in a 110 but I can unbolt the steering pump and leave it connected.
Take the bonnet off or tie it up against the screen.
Oil cooler and pipes will pee oil everywhere so watch out for that.
Have you got the lifting eyes still attached? Sometimes missing, one lh rear of engine and one on the front.

Thanks. Yeh still got lifting eye attached thankfully. Batteries are already out and will defo need to take bonnet off

Flossie · Nov 4, 2018

I also found its easier if you unbolt the passenger side engine mount off the block once you've got the weight, the rubber mount studs can bind coming out and even worse going back in. Removing the steel mount avoids this and lots of cursing.

Flossie · Nov 4, 2018

If you're stripping the engine down consider cracking the crank bolt (30mm) cos it's tight before you remove the engine.

flat · Nov 4, 2018

if you can buy or borrow one, one of those adjsutable angle things that go on the engine hoist so you can raise and lower the front and rear of the engine, mak eit much easier getting it in and out. i didnt do anything to the gearbox on mine, i removed the floor sections, undid the bellhousing bolts then with the engine mounts undone and removed with the weight on the hoist i was able to shuffle the engine off the gearbox. Took a lot of wiggling etc.
I took the rad and grille frame etc out and took the engine straight out the front. its 10 mins more unbolting but essential imo

Marmaduke · Nov 4, 2018

payydg said:
As in just screwed in? are there threaded holes at the back?

You need long bolts through the stand mounting plate into the back of the block that the flywheel housing uses. If you were closer I've got one of those levellers you could have borrowed. Mine was from machine mart

payydg · Nov 4, 2018

flat said:
if you can buy or borrow one, one of those adjsutable angle things that go on the engine hoist so you can raise and lower the front and rear of the engine, mak eit much easier getting it in and out. i didnt do anything to the gearbox on mine, i removed the floor sections, undid the bellhousing bolts then with the engine mounts undone and removed with the weight on the hoist i was able to shuffle the engine off the gearbox. Took a lot of wiggling etc.
I took the rad and grille frame etc out and took the engine straight out the front. its 10 mins more unbolting but essential imo

I’ve ordered one of those, looked handy. How did you wiggle it off? just brute force, is it damaging to use a pry bar between bell housing and box?

Marmaduke · Nov 4, 2018

payydg said:
I’ve ordered one of those, looked handy. How did you wiggle it off? just brute force, is it damaging to use a pry bar between bell housing and box?

If everything is lined up you shouldn't really need to, it's worth putting a block of wood or a jack underneath the front of the bell housing to stop the gearbox falling forwards and the input shaft hitting the clutch spines

flat · Nov 4, 2018

payydg said:
I’ve ordered one of those, looked handy. How did you wiggle it off? just brute force, is it damaging to use a pry bar between bell housing and box?

Used a soft face raw hide mallet to belt it the all it needed was a small flat blade screwdriver to get it moving then it all wiggled off eventually

flat · Nov 4, 2018

Marmaduke said:
If everything is lined up you shouldn't really need to, it's worth putting a block of wood or a jack underneath the front of the bell housing to stop the gearbox falling forwards and the input shaft hitting the clutch spines

Yes good tip, except I used a bottle jack from underneath iirc

payydg · Nov 9, 2018

Does anyone know how much a drained 200tdi engine weighs?

The hard part is going to be getting the engine up some steps, down my garden path and into my workshop. Just looking at trolleys.

Beneagles · Nov 9, 2018

payydg said:
The hard part is going to be getting the engine up some steps, down my garden path and into my workshop. Just looking at trolleys.

Don't think Tesco or Asda ones will take the weight. One of the flat-bed type from B&Q or Booker might do the trick - decent wheels, low centre of gravity and best of all given your location - no pound coin needed!!

payydg · Nov 9, 2018

Beneagles said:
Don't think Tesco or Asda ones will take the weight. One of the flat-bed type from B&Q or Booker might do the trick - decent wheels, low centre of gravity and best of all given your location - no pound coin needed!!

Haha yeh I did actually mean the flat bed ones. There’s a 300kg one in B&Q.

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