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PostPosted: Sun May 02, 2021 12:47 pm 
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Barrelling Along
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Joined: Fri Nov 23, 2007 6:13 pm
Posts: 21238
Location: Maidstone
Car Models: 9-5 Aero
Its looking like I will be able to undertake replacement of the engine that's currently in my Aero. This is a good thing as its now on 227k and has a slightly unhealthy thirst for oil.

I have a replacement Engine from a 2003 2.0 to go in.
It was a very well cared for engine and only has 120k on the clock. The insides look like new 8)
It has been dry stored with oil down the bores since it was removed from the donor car. I also have the loom for it too, so things should be straightforward.........

I have a list in my head of things I will fit/change before it goes into my car....... anyone spot anything obvious that I have missed?

New clutch
New genuine slave cylinder
Braided clutch flexi hose
New oil pressure sensor
New timing chain oil seals
New crank oil seals
New oil pump O ring
New oil pick up O rings x3 (will be giving the sump a once over)
New oil cooler O rings? (Unsure whether to just unbolt the filter housing and leave it on the car?)
New cam cover gasket & bung
New serpentine belt (pulleys to be checked)
New exhaust manifold studs & gasket
New spark plugs
Remap to suit a 2.0 TD-04
New fuel filter
New air filter
Coolant thermostat

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Rich
Prefers driving over polishing or reading.


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PostPosted: Sun May 02, 2021 1:01 pm 
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Joined: Thu Feb 14, 2008 10:47 am
Posts: 7363
Location: Queenborough, Kent
Car Models: 9k, 2 x 9-5's & a Jaaag
Depends on how long you intend to keep it, but I'd be measuring the timing chain tensioner extension and giving consideration to replacing the timing and balance chains (plus associated paraphernalia) as you'd need to pull it again to do those later.

Also, maybe fit a new genuine Bosch CPS. What's the alternator like?

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'98 9000 2.3T CSE, stage 3
'08 Jaguar XFR
'10 9-5 2.3T Turbo Edition, stage 3+
'04 9-5 Aero manual


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PostPosted: Sun May 02, 2021 1:10 pm 
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Barrelling Along
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Joined: Fri Nov 23, 2007 6:13 pm
Posts: 21238
Location: Maidstone
Car Models: 9-5 Aero
It's going to sit in there whilst I rebuild the original engine with some b234 pistons and rods, so at least a few years :lol:
The 2.3 will be getting a new timing chain, guides and balance shaft delete.

The temporary 2.0 is one of the nicest I have ever seen the insides of - the tensioner has already been checked and its in fine fettle, the chain is taught and everything is a lovely golden yellow colour.


I may swap the CPS from my existing engine, as its only about 18 months old.


The alternator is in good condition and has approx 90k fewer miles than the one on the 2.3.

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Rich
Prefers driving over polishing or reading.


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PostPosted: Sun May 02, 2021 1:19 pm 
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Joined: Sun Jan 26, 2014 9:41 am
Posts: 5377
Location: Royal Tunbridge Wells
Car Models: '03 9-5 2.3 Vector Auto Estate Noob Stg 1, Suzuki S Cross, '81 TR7 DHC
Did the 2.0 come with the turbo or are you using the Aero one? Either way the ECU might need looking at, if the 2.0 GT17 turbo a Noob Stage 1 will give a bit more performance and match it to the 2.0 engine, and if you use the Aero TD04 presumably it might need some map adjustment to suit the 2.0 engine anyway? Maybe get a spare T7 ECU and get Karl to look at it appropriately.

Assume the 2003 2.0 has the updated PCV kit fitted?

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Alan

'03 9-5 2.3t Vector Estate Auto Noob Stg 1
'01 9-3 2.0t SE Vert Auto
'81 Triumph TR7 DHC


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PostPosted: Sun May 02, 2021 2:27 pm 
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Barrelling Along
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Joined: Fri Nov 23, 2007 6:13 pm
Posts: 21238
Location: Maidstone
Car Models: 9-5 Aero
It came with a GT17, but I will be moving the TD-04 over.
You may note that I have already mentioned about a remap :wink:
I took the ECU from the donor car too.

I may be muddling the year the engine came from as it has the later breather system fitted. Ie with the annoyingly fragile red ring clips into the cobra.

Have added the thermostat I forgot to the list :bag:

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Rich
Prefers driving over polishing or reading.


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PostPosted: Sun May 02, 2021 4:21 pm 
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Joined: Mon May 30, 2005 1:37 pm
Posts: 2422
Location: UK, USA, Deutscheland
Car Models: sorted 9000 Aero; 9000R
engine mounts the same? Replace all if worn?


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