Engine Swap - Mazda3 Forums : The #1 Mazda 3 Forum
 
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post #1 of 4 (permalink) Old 04-26-2019, 12:24 AM Thread Starter
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Engine Swap

Hello, guys.
'06 Mazda 3, 2.3.
Background: Crankshaft and bearings damaged, due to son running it without oil. First thought of doing the 2.5 swap, but I was able to find an under-$500 Mazda 2.3 engine on LKQ. It was that cheap because it was in Canada, so it would take longer to get here. I wasn't in a hurry, so I ordered it.
I swapped the transmission from the old to the new and mounted the whole thing in the car. Connected the wires all around, the fuel line, the coolant lines (and thermostat), the AC compressor, the alternator, the exhaust header, everything.
The hardest thing so far, has been the insertion of the drive shafts. This was VERY difficult, mostly the one with the clip, the driver side one.
I was getting ready (and very excited) to put in the fluids, connect the battery, and give it a try, but found that the clutch pedal was on the floor. Did the "normal" stuff (check the fluid level, purge it), but when I was purging it I saw that the slave cylinder looked bad. Took it out and yes, it was damaged.
I also tried to move the release fork, but I couldn't. That made me think that I probably did something wrong when I transferred the transmission. However, I can actually actuate it if I use a big ass bar that I have, but it doesn't move it in a 'soft' way. This makes me think that the small slave cylinder is probably too weak to exert the needed force. On the other hand, it makes sense to me that the effort needed is significant, because what it is doing, is pressing the clutch disks together. The 2 ideas don't 'gel' in my head (clutch fork hard to move, and slave cylinder not looking strong enough)

I really hope someone here can shed some light on this for me. According to the workshop manual, there's only the fork and the bearing, and nothing else right there.
My current plan is simply to order a slave cylinder replacement, mount it, and see if it works. If it doesn't, then I suppose I'll have to take the whole thing down again. I don't think I have a way of 'just' taking down the transmission because I'm doing this job in my garage.

Thank you, to anyone that can give me some advise.

Last edited by vasama; 04-26-2019 at 12:20 PM.
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post #2 of 4 (permalink) Old 03-23-2020, 04:30 PM Thread Starter
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Because of this car not being something that I really need to move around but rather, a personal project of mine, it's been sitting in my garage all this time. Current events have freed a bunch of my time, so I have hit it again. I ended up taking that engine out to check the clutch, but there was nothing wrong with it. Digging more in the Internet, it seems that it was a simple bleeding problem. I ended replacing both cylinders (the master is a real bitch to change it), and the engine is back in. I'm in the process of reconnecting everything, but I hit my first question: The Speed Sensor wire has a plastic snap that I'm unsure where it goes. It can't be in the shift cables bracket, because it is a bit too far from the sensor itself. Also, the neutral switch wire has a little metal plate with a hole in it, that is clearly to lock the wire somewhere, but I'm also unsure where it goes.
I think that at the end of the day, if I don't figure out where those two guys go, I'll just zip-tie them to somewhere close, but probably someone here knows, or can take a look at their engine and tell me.
Thank you all in advance.
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post #3 of 4 (permalink) Old 03-27-2020, 11:24 PM Thread Starter
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Hopefully this forum will show signs of life.

I have advanced a lot. A few things left that I should be able to complete tomorrow. BUT I have 2 new questions:

The valve cover has an outlet for the crankcase vapors to go back to the air inlet duct. That outlet has a piece that snaps to it, where the hose is attached. I needed to replace the valve cover, and I had to transfer that connector to the new cover. I haven't been able to put it in, no matter how much I press it in. I'm thinking that I'll have to remove the cover again, to try to press the thing somehow. Does anyone know of a trick to secure this thing in place?
The second question is about a sensor that I have no idea what it is or where it goes. Seems to be some sort of temperature sensor. I'm attaching a photo of it, hoping that someone tells me what it is.

Thanks in advance.
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post #4 of 4 (permalink) Old 05-17-2020, 06:12 PM
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Garage
Thank you so much for posting this. I don't have answer to your question but just wanted to you know that this made for an excellent read. Where are you now on the swap?
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