04 2.3l swap to 2.5l successful - Page 119 - Mazda3 Forums : The #1 Mazda 3 Forum
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post #1181 of 1565 (permalink) Old 01-16-2017, 09:48 PM
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Originally Posted by madmatt2024 View Post
So the timing was off then?
Yup. It was just off enough so the engine ran, but ran poorly. Gave some mystifying scan data, made some strange noises, heated the living hell out of the cat, no power, and no throttle response, which all led me on a wild goose chase for a while.

Re-timed the crank pulley and within a couple of hours it was running perfectly, all scan data normal, and I was driving it all around town without a single problem.

I paid somebody to do the timing for me and he botched it. I trusted him which was why I didn't suspect timing to begin with. Plus, scan data showed timing as being perfect! After doing it myself I can see the many ways he went wrong.

I re-timed it myself and it came out perfect. Not bragging but just saying I should have trusted myself to do in the first place. There is great peace of mind in knowing that you did it yourself and did it right.

2.3 injectors
2.5 intake manifold
Intake/TB adapter
2.3 TB

Will post some scan data showing just how it's running.

2004 6i (2009 Fusion 2.3 swapped), 2005 3s (2011 Fusion 2.5 swapped), 2006 6s.
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post #1182 of 1565 (permalink) Old 01-16-2017, 10:44 PM
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It's one of the downsides of the crank not being keyed. You use the tools to line up the cams, line up the crank, line up the pulley, and then torque down the crank pulley, and theoretically it's perfectly in time. But because it's not keyed, it has that potential to shift ever so slightly and end up out of time.

2.5 swap TB adapters, alu dipstick handles, and more!

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post #1183 of 1565 (permalink) Old 01-25-2017, 08:43 PM
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Not sure if this is too far off of the OP, but can anyone tell me if there are any major differences from the OP when doing a 2.0 to 2.5 swap?

Do you use the original 2.0 exhaust and intake manifolds?

What is the newest engine you can use? Is it up to 2013?

I have an 08 2.0 ATX if it matters.

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post #1184 of 1565 (permalink) Old 01-25-2017, 11:02 PM
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You /CAN/ use the 2.0 manifold, but you're better off retaining the 2.5 intake manifold as it's port matched and wont be a restriction. I replied to your other post.

2.5 swap TB adapters, alu dipstick handles, and more!

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post #1185 of 1565 (permalink) Old 01-31-2017, 11:38 AM
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Do we have any confirmed 2.0 to 2.5 swaps?

This question is coming up more and more and I don't know squat about the 2.0's.

From what I've read the good is:

The 2.0 to 2.5 swap can be done. (2.0, 2.3, and 2.5 block are the same, everything bolts on)
Fusion 2.5's up to the 2013 are okay to use place of the 2.0's.
There is the issue of the VVT connector being different and requiring a pigtail swap.

The bad is:

The pigtail swap.
Not all 2.0's had VVT so possibly no connector at all.
Some 2.0's may not have DBW and so have cable operated TB's.

Otherwise, the challenges of a 2.0 to 2.5 are the same:

Swap oil pan and pickup if A/C present.
Intake cam/timing wheel on 04's and 05's. 06' on, no intake cam worries.
Timing cover.
Crank pulley.
Intake choice. (keep the 2.5 is best I think)
Injector choice. (2.3's work well but would the 2.0's keep up with the 2.5?)
Keep 2.3 TB.
VVT pigtail.
Pilot bearing if M/T.
Etc.

That's all I've got.

Any big additions/concerns to the 2.0 to 2.5 swap challenge?

2004 6i (2009 Fusion 2.3 swapped), 2005 3s (2011 Fusion 2.5 swapped), 2006 6s.
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post #1186 of 1565 (permalink) Old 02-03-2017, 08:47 AM
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Quote:
Originally Posted by DanHas3 View Post
Do we have any confirmed 2.0 to 2.5 swaps?

This question is coming up more and more and I don't know squat about the 2.0's.

From what I've read the good is:

The 2.0 to 2.5 swap can be done. (2.0, 2.3, and 2.5 block are the same, everything bolts on)
Fusion 2.5's up to the 2013 are okay to use place of the 2.0's.
There is the issue of the VVT connector being different and requiring a pigtail swap.

The bad is:

The pigtail swap.
Not all 2.0's had VVT so possibly no connector at all.
Some 2.0's may not have DBW and so have cable operated TB's.

Otherwise, the challenges of a 2.0 to 2.5 are the same:

Swap oil pan and pickup if A/C present.
Intake cam/timing wheel on 04's and 05's. 06' on, no intake cam worries.
Timing cover.
Crank pulley.
Intake choice. (keep the 2.5 is best I think)
Injector choice. (2.3's work well but would the 2.0's keep up with the 2.5?)
Keep 2.3 TB.
VVT pigtail.
Pilot bearing if M/T.
Etc.

That's all I've got.

Any big additions/concerns to the 2.0 to 2.5 swap challenge?
Regarding the injectors, the smaller 2.0 injectors /COULD/ work, but the ecu would be cranking up the duration by a significant margin. After all, we're talking a full 25% increase in displacement. The 2.5 uses the newer style injectors (black body with a colored band, in my case it was a grey or purple band. Hard to tell, was faded), you can use the older style, but when I was testing which injectors to use, the older style (fatter, colored body) didn't seem to seat as well, and I think were shorter. In my case, the best solution was late model 2.3 injectors (thin black body, orange band). Everything came back within margin, car doesn't throw rich or lean codes (with 2.5 injectors, I would run "rich at idle" and "rich off idle").

The Bosch number for the later style 2.3 injectors is 0280158105. Here is a link for them on ebay (for however long it lasts).
Bosch Flow Matched Fuel Injector Set for 06 10 Ford Mazda 2 0 2 3 0280158105 4 | eBay

2.5 swap TB adapters, alu dipstick handles, and more!

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post #1187 of 1565 (permalink) Old 02-03-2017, 12:20 PM
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Quote:
Regarding the injectors, the smaller 2.0 injectors /COULD/ work, but the ecu would be cranking up the duration by a significant margin. After all, we're talking a full 25% increase in displacement.
Good info and thanks for sharing your expertise with this!

Now we need some folks to step up and share their 2.0 to 2.5 swap experiences.

2004 6i (2009 Fusion 2.3 swapped), 2005 3s (2011 Fusion 2.5 swapped), 2006 6s.
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post #1188 of 1565 (permalink) Old 02-16-2017, 12:45 PM
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Quote:
Originally Posted by DanHas3 View Post
Keep 2.3 TB.
Stupid question: is the 2.0L throttle body the same as a 2.3L? Mine is 2007, so it's drive-by-wire if that makes a difference. Thanks.

'07 Mazda 3i
Previously driven by sensible wife, now being modded by gearhead husband. Uh oh...
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post #1189 of 1565 (permalink) Old 02-17-2017, 07:35 PM
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Quote:
Originally Posted by jennyzoomzoom View Post
Stupid question: is the 2.0L throttle body the same as a 2.3L? Mine is 2007, so it's drive-by-wire if that makes a difference. Thanks.
Poking around on eBay, I found this, so maybe they are the same:

New Throttle Body 2006-2013 Mazda 3 Mazda 5 Mazda 6 Non Turbo 2.0 2.3L L3R413640 (Fits: Mazda 3)

Mazda online parts sites indicate that the part number is the same. A call to a Mazda dealership parts counter to confirm should do it.

I've got a spare TB lying around if you want to exchange bore dimensions and or part numbers off of the TB's.

2004 6i (2009 Fusion 2.3 swapped), 2005 3s (2011 Fusion 2.5 swapped), 2006 6s.

Last edited by DanHas3; 02-17-2017 at 07:45 PM.
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post #1190 of 1565 (permalink) Old 02-21-2017, 01:14 PM
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Thanks very much! I didn't take it off the car, but measuring what I could get to, the bore starts at 65mm and necks down to about 52mm (tough to measure accurately).

When I saw the part number in the ebay link starting with "L3", I wasn't sure if it was specific to the 2.3L since that's how it's referred to throughout the FSM. Sure enough, my stock 2.0L throttle body is indeed the same part number.

'07 Mazda 3i
Previously driven by sensible wife, now being modded by gearhead husband. Uh oh...
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